Discover how hidden inefficiencies and preventable breakdowns are draining profits across manufacturing.

Downtime is costing more than you think

Every manufacturer knows that downtime is costly, but few realize just how much it’s eating into their bottom line. Across North America, facilities typically spend 5–15% of their annual operating budget on maintenance alone.¹ That might sound reasonable, until you look at how often those dollars are spent reactively, addressing failures that could have been prevented with better planning and daily practices.

Maintenance can eat up 40% of production costs

Maintenance expenses can range from 15% to as much as 40% of total production costs in some industries.² That puts maintenance on par with labor and raw materials as one of the largest controllable costs in manufacturing. Yet many plants still rely on outdated routines, deferred upkeep or a “fix it when it breaks” mindset that ends up costing more over time.

The true cost of downtime: $50k per minute

Downtime costs add up fast. In the automotive sector, every minute of lost production can mean up to $50,000 in losses.³ That’s $3 million per hour. And with increasingly streamlined operations, the average cost of downtime across industries now exceeds $2.3 million per hour.⁴

Small changes, big impact

Preventing failure doesn’t always require big investments. Simple, consistent actions, like daily wipe-downs with task-specific tools, can make a measurable difference. Extending equipment life, preventing contamination and reducing unplanned maintenance starts with the habits that your teams build every day.