what are they and how to reduce them?
Posted: Tue Jan 07, 2025 6:09 am
Industrial maintenance costs: what are they and how to reduce them?
Modern industry is constantly faced with the challenge of maintaining its equipment and assets in optimal conditions. Here, managing industrial maintenance costs can be the difference between achieving profitability or wasting months of effort and ending up with losses.
In this article, we will explore the key aspects of industrial maintenance costs and provide you with practical strategies to optimize your processes and your assumptions.
Keep reading to discover how you can maximize the value of your maintenance investments!
What are the industrial maintenance costs?
Now, industrial maintenance costs are those related to the conservation and restoration of goods in a company or industry . As its name suggests, it refers to those disbursements that the organization must make to maintain the key machinery of its platform in good working order to guarantee production and quality.
Although at first glance they may seem simply worn out, in reality they represent an inversion in the medium and wide area. Why? Therefore, because without machinery, equipment, vehicles, tools and more, the industry would be unable to fulfill its promise to its customers.
What are the types of maintenance costs?
Depending on the nature and function of the task, it is possible phone leads to incur various types of industrial maintenance costs, such as:
Direct maintenance costs
It refers to those costs that are directly related to maintenance and repair activities, and are subdivided into:
Preventive maintenance : how to plan expenses to prevent failures and keep assets in good condition.
Corrective maintenance : those costs associated with repairing unexpected failures or failures.
Predictive maintenance : investment in technologies to monitor the state of assets and predict failures before they occur.
Indirect maintenance costs
Generally, failure or inoperability of equipment or machinery can occur and can be divided and grouped into:
Production loss due to unplanned stoppages.
Costs generated cause damage to the company's reputation.
Additional costs for urgent subcontracting or rental of replacement equipment.
Induced maintenance cost
The costs incurred in industrial maintenance are those additional unscheduled expenses that may arise during operations, for example:
Maintenance errors.
Delays due to lack of resources.
Waste of time and materials .
That said, let's see how these costs are determined.
How to calculate industrial maintenance costs?
Now, when you understand the importance of knowing industrial maintenance costs in your business, especially to optimize operations and guarantee efficiency, we can calculate them.
Price of spare parts
Calculate the cost of replacements that will be replaced during maintenance. Here we consider specific parts, components and consumables necessary to keep the equipment running.
Labor cost
Evaluate the time dedicated by technicians and workers to maintenance. Luego, multiply the hours worked by your hourly wages, including both preventive and corrective maintenance.
Cost associated with tools, materials and equipment
At this point, expenses related to tools and equipment used for maintenance are taken into account, which may include manual tools, diagnostic software, measurement equipment and others.
Administrative, indirect and induced costs
Do not forget the indirect costs, such as maintenance management and planning. Here we summarize the salaries of administrative staff, tracking software and other resources necessary to organize maintenance activities.
Furthermore, you are aware of induced costs, such as maintenance errors or delays due to lack of resources.
Other costs involved in the maintenance process
This may vary depending on the industry and company. However, it generally refers to those additional expenses related to logistics , transportation, storage and any other relevant aspect.
Remember that a comprehensive approach to cost management will help you optimize your operations and maintain efficiency in industrial maintenance. To do this, apply several industrial production indicators to evaluate the global performance of your company.
How to reduce industrial maintenance costs?
Considering that according to Researchgate , industrial maintenance costs in factories are estimated to be between 15% and 70% of the cost of goods produced , reducing these numbers is crucial. Here we tell you how.
Modern industry is constantly faced with the challenge of maintaining its equipment and assets in optimal conditions. Here, managing industrial maintenance costs can be the difference between achieving profitability or wasting months of effort and ending up with losses.
In this article, we will explore the key aspects of industrial maintenance costs and provide you with practical strategies to optimize your processes and your assumptions.
Keep reading to discover how you can maximize the value of your maintenance investments!
What are the industrial maintenance costs?
Now, industrial maintenance costs are those related to the conservation and restoration of goods in a company or industry . As its name suggests, it refers to those disbursements that the organization must make to maintain the key machinery of its platform in good working order to guarantee production and quality.
Although at first glance they may seem simply worn out, in reality they represent an inversion in the medium and wide area. Why? Therefore, because without machinery, equipment, vehicles, tools and more, the industry would be unable to fulfill its promise to its customers.
What are the types of maintenance costs?
Depending on the nature and function of the task, it is possible phone leads to incur various types of industrial maintenance costs, such as:
Direct maintenance costs
It refers to those costs that are directly related to maintenance and repair activities, and are subdivided into:
Preventive maintenance : how to plan expenses to prevent failures and keep assets in good condition.
Corrective maintenance : those costs associated with repairing unexpected failures or failures.
Predictive maintenance : investment in technologies to monitor the state of assets and predict failures before they occur.
Indirect maintenance costs
Generally, failure or inoperability of equipment or machinery can occur and can be divided and grouped into:
Production loss due to unplanned stoppages.
Costs generated cause damage to the company's reputation.
Additional costs for urgent subcontracting or rental of replacement equipment.
Induced maintenance cost
The costs incurred in industrial maintenance are those additional unscheduled expenses that may arise during operations, for example:
Maintenance errors.
Delays due to lack of resources.
Waste of time and materials .
That said, let's see how these costs are determined.
How to calculate industrial maintenance costs?
Now, when you understand the importance of knowing industrial maintenance costs in your business, especially to optimize operations and guarantee efficiency, we can calculate them.
Price of spare parts
Calculate the cost of replacements that will be replaced during maintenance. Here we consider specific parts, components and consumables necessary to keep the equipment running.
Labor cost
Evaluate the time dedicated by technicians and workers to maintenance. Luego, multiply the hours worked by your hourly wages, including both preventive and corrective maintenance.
Cost associated with tools, materials and equipment
At this point, expenses related to tools and equipment used for maintenance are taken into account, which may include manual tools, diagnostic software, measurement equipment and others.
Administrative, indirect and induced costs
Do not forget the indirect costs, such as maintenance management and planning. Here we summarize the salaries of administrative staff, tracking software and other resources necessary to organize maintenance activities.
Furthermore, you are aware of induced costs, such as maintenance errors or delays due to lack of resources.
Other costs involved in the maintenance process
This may vary depending on the industry and company. However, it generally refers to those additional expenses related to logistics , transportation, storage and any other relevant aspect.
Remember that a comprehensive approach to cost management will help you optimize your operations and maintain efficiency in industrial maintenance. To do this, apply several industrial production indicators to evaluate the global performance of your company.
How to reduce industrial maintenance costs?
Considering that according to Researchgate , industrial maintenance costs in factories are estimated to be between 15% and 70% of the cost of goods produced , reducing these numbers is crucial. Here we tell you how.