Table 4.
Costs and Losses Associated with Maintenance –Estimated with no Stratification and no Monte Carlo analysis from Thomas and Weiss (2020)
| Estimate ($2016 Billion) | 90 % Confidence Interval | ||
|---|---|---|---|
| Costs | 74.5 | 49.8 | 98.8 |
| Direct Maintenance Costs | 57.3 | 42.4 | 72.2 |
| Costs due to Faults and Failures | 16.3 | 7.1 | 25.5 |
| Inventory Costs | 0.9 | 0.3 | 1.1 |
|
| |||
| Losses | 119.1 | 43.9 | 197.3 |
| Unplanned Downtime | 18.1 | 10.4 | 27.8 |
| Labor | 13.5 | 7.1 | 22.1 |
| Capital Depreciation Buildings | 2.5 | 1.8 | 3.1 |
| Capital Depreciation Machinery | 1.0 | 0.7 | 1.2 |
| Energy | 1.1 | 0.8 | 1.4 |
| Defects | 0.8 | 0.0 | 2.7 |
| Lost Sales | 100.2 | 33.5 | 166.8 |
| Due to Defects | 31.2 | 3.6 | 58.7 |
| Due to Delays | 69.0 | 29.8 | 108.1 |
|
| |||
| Total Costs and Losses | 193.6 | 93.6 | 296.2 |
Source: Thomas, Douglas and Brian Weiss. “Economics of Manufacturing Machinery Maintenance: A Survey and Analysis of U.S. Costs and Benefits.” NIST Advanced Manufacturing Series 100–34. https://doi.org/10.6028/NIST.AMS.100-34