Maintenance cost analytics
See what maintenance really costs, machine by machine.
Maintenance cost analytics in MaintenanceIQ add up the parts used and the charges recorded against each breakdown, and show the total by asset and by area. It helps your maintenance manager defend a budget with facts, and helps your plant head see which machines are worth investing in.
The problem
The budget question nobody can answer by machine
Your maintenance manager is asked to cut spend, or to justify a new compressor, or to explain why the stores bill went up. The finance view shows totals by account. It does not show that one melter took most of the spares this quarter, or that a conveyor nobody complains about stops often enough to cost more than its parts.
Most maintenance cost hides in scattered places. The parts are in the stores ledger. Other charges sit in invoices and notebooks. What a single breakdown really cost is usually not written anywhere at all.
When every cost is tied to the breakdown that caused it, the picture changes. You stop arguing about the total and start talking about the few machines that drive it.
What is counted
What maintenance cost analytics add up
Each cost component comes from a record your team already creates. Together they are how your team confirms what each breakdown cost.
| Component | Comes from | Rolled up by |
|---|---|---|
| Parts | Parts used on each breakdown | Asset and area |
| Charges | Charges your team records against each breakdown | Asset and area |
Costs show in your tenant's currency, chosen once in organization settings. INR is the default.
Where it goes
By asset and by area, where the spend actually happens
Totals roll up by asset and by area, so your maintenance manager can see whether the cost sits in one machine, one section of the plant, or everywhere. The asset view answers "which machine". The area view answers "which part of the plant".
Because every breakdown carries its own cost, a machine that fails often no longer looks cheap just because each repair was small. That changes which jobs get planned first.
- Parts used and breakdown charges side by side
- Rolled up by asset and by area
- Built from the breakdowns your team logs, no separate entry
- Each figure traces back to the breakdown it came from
Worked example
Two machines, one quarter
Worked example (illustrative)
Over one quarter, the IM-02 melter and the CV-03 conveyor (both illustrative machines) log a few breakdowns each. Your team records the parts used and the charges against each one, in your tenant currency.
| Asset | Breakdowns | Parts used | Charges recorded | Total |
|---|---|---|---|---|
| IM-02 melter | 3 | 18,000 | 42,000 | 60,000 |
| CV-03 conveyor | 6 | 4,000 | 9,600 | 13,600 |
The conveyor breaks down twice as often, yet the melter costs more than four times as much: 60,000 against 13,600. Each figure traces back to the breakdowns behind it. That is the case your maintenance manager takes to the plant head for a preventive task, a critical spare or a reliability project on the melter.
Deciding what to fix
Cost is one lens, so use it with the others
A high cost on its own does not tell you what to do. Read it next to how often the machine fails and how much it matters to production.
MaintenanceIQ keeps these lenses on the same record, so the comparison does not need a spreadsheet.
- Criticality: each asset carries an A, B or C criticality. A costly C asset may be fine to run to failure. A costly A asset is not.
- Failure pattern: the bad-actor ranking and MTBF and MTTR show whether cost comes from frequent small failures or rare large ones.
- Spares: spares optimization shows whether parts spend is driven by real consumption or by stock that never moves.
- Downtime: clean breakdown records keep the cost of each breakdown honest.
Frequently asked questions
What goes into the maintenance cost figure?
The parts used and the charges recorded against each breakdown. The total is shown by asset and by area.
How do we confirm what a breakdown cost?
Record the parts used and any charges against the breakdown itself. Those entries are what the cost figure is built from, so each total traces back to the breakdowns behind it.
Which currency are costs shown in?
One currency per tenant, chosen from a catalog in organization settings. INR is the default. Every cost, report and dashboard uses it.
Does this replace our finance system?
No. It gives maintenance a clear view of where its spend goes and what each breakdown costs, so you can decide where to act. It does not post entries to your accounts.