Industrial facilities maintenance
- Net saving for the year, programme paid
- $21,300
- Reactive repair cost for the year, as things stand
- $153,000
- Preventive programme cost for the year
- $70,500
Every figure on this page is computed from the inputs entered, by the method stated below it. FMlane publishes no code requirement, no standard's interval, no breakdown rate and no replacement value: the intervals, the rates and the avoidance assumption are yours, and the defaults are a worked example to replace with your own figures. The condition index bands quoted in the prose are sourced in research/data/claims.tsv.
Industrial facilities maintenance is the search of the plant maintenance manager, where an asset that fails is a line that stops and the cost of a breakdown is mostly the downtime: parts and labor are a fraction of what an hour of stopped production costs. That changes the arithmetic without changing its shape. Assets times breakdowns per asset a year times the cost of a breakdown is reactive cost as things stand, and in a plant the cost per breakdown is large; the preventive programme per asset times the assets is prevention; the share of breakdowns the programme avoids, at your own assumption from your own history, is the saving. This guide is about what industrial facilities maintenance has to keep and work, and the free facility preventive maintenance worksheet on this site sets breakdown cost, downtime included, against programme cost from your own figures with no account.
Try the free condition index worksheet Free to use. No account, no card, no trial clock.
The cost of a breakdown, with the downtime in it
In a plant the breakdown cost is parts, labor and the production lost while the line is down, and the last is usually the largest. The worksheet takes one figure per breakdown; put the downtime in it and the reactive line reflects what a stoppage actually costs the plant rather than what the repair invoice says.
The assets that stop the line, and their breakdown history
Not every asset stops production, and the ones that do carry the argument. Filed against the asset, each reactive work order counts toward that asset's breakdowns a year; the paid plan keeps the history per asset so the programme can be aimed at the assets whose failures cost the most rather than spread evenly.
The programme, and the avoidance you can defend
The programme cost per asset comes from the maintenance plan worksheet; the avoidance assumption comes from your own before-and-after history, and the worksheet publishes no rate. Reactive cost less the avoided share less the programme is the net saving, and the paid plan keeps each year's figures so the assumption is checked against what happened.
Industrial facilities maintenance: common questions
What makes industrial facilities maintenance different?
The cost of a breakdown, which in a plant is mostly downtime rather than parts and labor, and the concentration of that cost on the assets that stop the line. The arithmetic is the same as any building's; the figures are larger and the worksheet takes them as your own inputs.
How do I put downtime into the breakdown cost?
Add the production lost per breakdown to the parts and labor as one figure and enter it as the cost of a breakdown. The worked example uses $850 with no downtime in it to show the arithmetic; a plant's figure is its own, and FMlane publishes none.
Does FMlane keep the plant's asset register?
FMlane Pro keeps buildings, assets with their condition and work orders with their status and history against each asset, at $24 a month for the whole team. It does not connect to plant sensors or control systems; the breakdown count comes from the work orders your technicians file.
FMlane Pro
Keeping what you make
The worksheets are free forever. Pro turns them into the record: every asset kept against the building with its condition and its last visit, every work order filed with its status and who did it, the preventive schedule with what is due, your name and logo on the paperwork, no watermark, and an export when the auditor, the board or the insurer asks.
- Download as PDF
- No FMlane watermark
- Save every worksheet and reopen it later
- Your organisation's name and logo on the paperwork
- Export every assessment and plan in one go
- Preventive-due and overdue reminders emailed to your technicians
- Connect your own Stripe account and get paid online
- Connect your QuickBooks Online or Xero
$24per month, whole team
Start FMlane Pro PricingRenews monthly at the price above until you cancel. We email you before any price change.
Will it do what you need for Industrial facilities maintenance?
Tell us what your maintenance plan needs and we will tell you straight whether FMlane Pro does it today, whether it is coming, or whether you need an engineer instead. A person reads these and replies.
Cite or embed this figure
On the worked example, 150 assets at 1.2 breakdowns a year and $850 a breakdown is $153,000 of reactive cost; a programme at $470 an asset is $70,500 and, avoiding 60% of breakdowns, leaves reactive cost at $61,200 and a net saving of $21,300, before a plant's downtime cost is put in.
Facility preventive maintenance (Net saving for the year, programme paid): $21,300, FMlane, worked example.
Cite as: "Industrial facilities maintenance, FMlane", updated 2026-09-04, https://fmlane.com/industrial-facilities-maintenance/.