Work out maintenance cost per unit instantly with clear inputs, formula shown and shareable results.
Maintenance cost per unit distributes total maintenance spend over output. Two benchmark ratios matter alongside it: maintenance as a percentage of replacement asset value, where 2-3% is typical and under 2% indicates good practice, and the preventive-to-reactive split, where mature operations run 70:30 or better.
Maintenance cost per unit
Cost per unit = total maintenance cost / units produced
Asset ratio
Maintenance % of RAV = maintenance cost x 100 / replacement asset value
No. Cutting preventive maintenance lowers spend for a year or two, then breakdowns, scrap and downtime cost far more. Judge spend against availability and total cost of ownership.
It normalises for plant size and age, letting you benchmark against other sites and industries in a way that absolute spend cannot.