The cost of missed PMs is the expected dollar value of reactive failures driven by preventive maintenance that did not get done.
Every PM you skip saves a few hundred dollars today and rolls the dice on a few thousand dollars tomorrow. Enter the number of PMs deferred, the cost of a reactive failure, and the probability that skipping leads to one. The calculator sizes the risk so you can defend the PM budget.
It costs the expected value of the reactive failures it causes. The trap is that skipping a PM has no visible consequence today. The equipment keeps running. The failure the PM was meant to prevent shows up weeks or months later as an unplanned breakdown, and by then nobody connects it to the PM that was deferred in a scheduling crunch three months ago. This calculator makes that connection visible by putting a dollar figure on the accumulated risk.
Nothing happens immediately, which is why it feels safe. But the failure mode the PM was designed to catch accumulates unchecked. Over time, a percentage of skipped PMs result in reactive failures: unplanned breakdowns that cost more to fix, take longer to repair, and often cause collateral damage to adjacent components. The probability depends on the equipment criticality and the failure mode the PM addresses. A skipped oil change on a critical pump carries different risk than a skipped visual inspection on a non-critical handrail.
Multiply the number of PMs skipped by the probability that skipping causes a failure, then multiply by the average cost of that reactive failure. Subtract the PM cost you avoided by not doing the work. The result is the expected net cost of the deferred maintenance. This is a risk-sizing exercise, not a prediction of specific events. Use it to frame the conversation when someone suggests cutting the PM budget to save money.
This calculator sizes the cost of skipping PMs. The Maximo KPI Guide to PM Compliance covers the full compliance improvement process: why PMs get skipped, the Maximo fields and queries that measure compliance, and the trigger-action matrix that turns a compliance number into a corrective action before the reactive cost hits.