Preventive Maintenance ROI Calculator — Fleet PM Program Savings

Calculate the ROI of preventive maintenance vs reactive/breakdown maintenance. Quantify avoided repair costs, downtime savings, and extended asset life.

Quick answer: PM programs save $8,000–$15,000/truck/year in avoided breakdowns and downtime. ROI typically runs 100–200% — making PM one of the highest-return fleet investments.

🔧 Preventive Maintenance ROI Calculator

Fleet Size (trucks)

Annual PM Cost Per Truck ($)

Oil changes, filters, inspections, scheduled parts

Breakdowns Per Truck/Year (current)

Avg Breakdown Cost ($)

Towing + repair + downtime + rental

PM Breakdown Reduction (%)

Good PM programs reduce breakdowns 50–75%

Revenue Lost Per Breakdown ($)

PM Program ROI

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Annual PM Cost

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Annual Savings

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How to Use This Calculator

Enter fleet size and PM cost — include all scheduled service costs.
Enter current breakdown frequency and cost — include towing, repair, downtime, and rental.
Set PM breakdown reduction — 50–75% is typical for structured PM programs.

Worked Example

10 trucks, $4,500 PM/truck, 4 breakdowns/truck, $3,500 repair, $1,200 downtime, 60% reduction.

PM cost: $45,000/yr
Breakdowns avoided: 24
Total savings: $112,800
Net + ROI: $67,800 / 151% ROI

Frequently Asked Questions

Oil/filter changes, air filter, fuel filter, coolant, transmission/differential fluid, greasing, brake inspection, tyre rotation and inflation check, and full vehicle inspection. Frequency by OEM specs and duty cycle.

In-house is cheaper for 5+ trucks with a maintenance bay. Shop-based works well for smaller fleets or when technician retention is difficult.