There can be few things in maintenance that give rise to more stress and annoyance than unplanned downtimes and their costs. Not all unplanned downtimes can be avoided – unless there is an unlimited budget for maintenance equipment and systems, that is. Unfortunately, such a scenario is only possible in theory.

We can approach the subject of unplanned downtimes through the associated costs. We need to distinguish “true downtime costs” (TDCs) from “hidden downtime costs” (HDCs).

Individual costs

The TDCs are costs that can be easily linked to their causes and thereby entered in the accounts. These costs must be clearly identified and categorized as such. Nevertheless, in some cases the amounts for these individual items are extremely large and, under certain circumstances, may even exceed the costs incurred through the loss of production itself. Not everyone involved is always aware of this, and this state of affairs should be made clear when communicating with the individual departments.

 The HDCs, on the other hand, cannot be entered as such in the accounts, nor are they always easy to understand. These are mainly indirect costs, and, what’s more, they are often incurred at a later point in time. This creates the potential for considerable cost-impairments over the long term.

Downtimes and measurement

To gain a good overview of the current (cost) situation in your company, you need the right information. You need to measure whatever it is which, in the final analysis, you want to avoid or reduce.

In fact, this really is a case of no sooner said than done: you just need the right tool. And that’s where MaintMaster comes in.

MaintMaster brings production and maintenance together

With MaintMaster, you not only have maintenance planning under control, but also the entire reporting process, from production to machine restart. A tool that not only enables you to manage processes, but also serves as a means of analysis. All the data collected can be re-created individually in a simple and clear manner – including important KPIs.


Conclusion: Measurement, analysis and the subsequent drawing of appropriate conclusions are the key to minimizing downtime costs.

Without a tool like that provided by MaintMaster, you won’t be able to effectively manage and reduce your downtimes in the long term.
We would of course be more than happy for you to contact us directly on this subject, so that we can convince you in person of MaintMaster and its features in a face-to-face web meeting.