Downtime
Downtime is any period during which an asset is unavailable for its intended function. It can be planned (scheduled maintenance, shutdowns, inspections) or unplanned (breakdowns, failures, waiting for parts). Downtime is typically measured in hours and expressed as a percentage of total available time, providing a key indicator of asset availability.
Why it matters
Unplanned downtime is one of the most expensive operational issues in asset-intensive industries. Beyond the direct repair cost, it causes idle labour, missed deadlines, knock-on delays to other projects, and potential safety incidents if workarounds are used. Understanding the causes and duration of downtime enables targeted improvements to maintenance, parts management, and operational planning.
How MapTrack helps
MapTrack tracks both planned and unplanned downtime against each asset, giving managers visibility into availability trends and the ability to identify which assets or failure types cause the most disruption.
Frequently asked questions
What is the difference between planned and unplanned downtime?
Planned downtime is scheduled in advance for maintenance, inspections, or upgrades and can be coordinated to minimise operational impact. Unplanned downtime occurs unexpectedly due to breakdowns or failures and is typically far more disruptive and costly. The goal of a mature maintenance program is to maximise planned downtime while minimising unplanned events.
How is downtime cost calculated?
Downtime cost includes the direct repair expense (parts, labour) plus the indirect costs of lost production or revenue, idle crew wages, equipment hire to cover the gap, contractual penalties for delays, and potential safety incident costs. For major plant and equipment, unplanned downtime can cost thousands of dollars per hour when all factors are considered.
Related terms
Mean Time Between Failures (MTBF)
Mean Time Between Failures (MTBF) is a reliability metric that measures the average elapsed time between inherent failures of a repairable system during normal operation. It is calculated by dividing the total operational time by the number of failures over a given period. MTBF is typically expressed in hours and is used to compare the reliability of assets, components, or equipment models.
Mean Time to Repair (MTTR)
Mean Time to Repair (MTTR) measures the average time required to diagnose and fix a failed asset and return it to operational status. It includes diagnosis, sourcing parts, performing the repair, and testing. MTTR is typically calculated by dividing the total repair time across all failures by the number of failure events in a given period.
Preventive Maintenance
Preventive maintenance (PM) is a proactive maintenance strategy in which assets are serviced at predetermined time or usage intervals to reduce the likelihood of failure. Tasks may include inspections, lubrication, filter changes, calibrations, and component replacements. PM schedules are typically based on manufacturer recommendations, regulatory requirements, or historical failure data.
Corrective Maintenance
Corrective maintenance refers to repair or restoration work carried out after a fault, defect, or failure has been identified in an asset. It may be triggered by an operator report, a failed inspection, or an unexpected breakdown. Corrective tasks range from minor adjustments to major overhauls, depending on the severity of the issue.
Equipment Utilisation
Equipment utilisation measures the extent to which available equipment is being productively used, typically expressed as a percentage of available time or capacity. It is calculated by dividing actual usage time (or output) by total available time (or maximum capacity). Utilisation data can come from meter readings, operator logs, GPS tracking, or telematics systems. It is a key operational efficiency metric in asset-intensive industries.
See how MapTrack handles downtime