| Maintenance Cost |
Low initial cost (no planning). High, unpredictable, and recurring repair costs. |
Regular planning and execution costs. Low to moderate initial investment. Often unnecessary spending on labor and parts. |
Initial investment in sensors and technology. Drastically reduced operating costs (10-40% savings). |
| Downtime Cost |
Very high. Causes unplanned and prolonged downtime. Loss of productivity (up to $50K/hour). |
Medium Low. Allows for planned downtime. However, it does not prevent unforeseen failures. |
Very low. Reduces unplanned downtime by up to 50%. Repairs are scheduled at the most optimal times. |
| Asset Lifespan and Value |
Low. Lack of maintenance accelerates wear and shortens the asset's life. |
Moderate to High. Scheduled maintenance extends the equipment's lifespan (20-30% more). |
Very high. Premature wear is prevented, extending the asset's lifespan (up to 60% more). |
| Productivity and Efficiency |
Very low. Performance decreases before a failure. Failures affect production and product quality. |
Moderate. Avoids most unexpected stops and maintains acceptable performance. |
Very high. Increases labor productivity (5-20%) and improves OEE (5-15%). |
| Safety and Occupational Risk |
Very high. Sudden failures endanger workers and can cause catastrophic accidents. |
Low. Regular inspections and maintenance reduce the risk of accidents. |
Very low. The ability to predict failures eliminates most safety risks before they occur. |
| Inventory and Parts Cost |
High. A spare parts inventory is required for emergency and unscheduled repairs. |
Moderate. It is based on statistical planning that often requires a safety stock. |
Low. Allows for just-in-time inventory management and parts acquisition. |
| Planning Level |
None. No prior planning required. |
High. Based on a schedule or usage, with predefined task lists. |
Very high. Maintenance is scheduled based on real-time data and failure prediction. |
| Required Technology |
None. It is based on manual response. |
CMMS software to manage work orders and calendars in the cloud with internet. |
IoT sensors, Edge computing, data platforms, AI, and Machine Learning all local without internet. |
| Return on Investment (ROI) |
Negativo. El "ahorro" inicial se pierde rápidamente en costos ocultos y perdidas de productividad. |
Moderate. It generates savings, but with the cost of inefficiency and premature interventions. |
Very high and measurable. It can generate a 10x ROI, with returns in a matter of months. |
