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Practical perspective from the Trufe team on this topic.
Coverage focus: AI · Manufacturing, Energy · Industry Analysis.
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Artificial Intelligence•6 min•Trufe Insights•Apr 1, 2026
Predictive Maintenance ROI — A No-Nonsense Calculator for Plant Managers
Industry Analysis perspective for Manufacturing, Energy with implementation guidance and internal references.
The Real Cost of Unplanned Downtime
- Average cost per hour of downtime by industry
- Cascading effects: lost production, quality defects, safety risks
Predictive vs. Preventive vs. Reactive (Quantified)
- Reactive: fix when broken ($$$, high downtime, safety risk)
- Preventive: fix on schedule ($$, over-maintenance, still has surprises)
- Predictive: fix before failure ($, optimized, data-driven)
The ROI Formula
current maintenance spend
production uptime gain
- Input: asset count, average downtime hours/year, cost per hour,
- Output: expected reduction in unplanned downtime, maintenance cost savings,
- Interactive calculator concept (for the web page)
What You Need to Get Started
- Sensor data (vibration, temperature, pressure, current)
- 6–12 months of historical maintenance logs
- A model that predicts Remaining Useful Life (RUL), not just anomalies
Case Example: Manufacturing Plant
Closing CTA:
→ Link to: /solutions/artificial-intelligence/machine-learning/demand-planning-optimization/
→ Link to: /industries/manufacturing-supply-chain/
Internal References
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