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Asset Tracking & Equipment Management Statistics

An hour of unplanned equipment downtime costs from around US$36,000 in fast-moving consumer goods to US$2.3 million in a large automotive plant, on Siemens and Senseye figures, while an Australian body corporate faces fines of up to AU$17,728,000 for a Category 1 offence under the Commonwealth Work Health and Safety regime for 2026-27. State and territory maxima differ.

MapTrack compiled the 71 figures on this page from 49 published sources. Each one is shown with the organisation that published it, the publication year and the source page MapTrack reviewed. Review status and material scope limits are shown with each figure.

Cited industry data on equipment theft, tool loss, downtime costs, maintenance benchmarks, compliance, and the ROI of digital asset tracking. Each entry links to the source MapTrack reviewed and shows its review status. Verified and source-reviewed entries include a pre-formatted citation. Unverified claim checks are not offered for syndication.

Need publisher-ready charts, calculator embeds or checklist previews? Visit the MapTrack citation centre.

Last updated: · 67reviewed figures with citation tools · 4claim checks withheld from syndication · Compilation licensed under CC BY 4.0

Use the complete source registry

This is a curated bibliography of third-party published material, not MapTrack customer, survey or telemetry data. Each row records the figure, publisher, year, source URL and its stable page anchor. Archive and source-check details are included where available.

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Equipment Theft Statistics

Source-reviewed theft costs, recovery rates and Australian data, plus claim checks on widely quoted figures.

Fleet Management Statistics

Scoped fleet evidence on maintenance, idling, utilisation, tracking coverage and safety.

Asset Tracking ROI Statistics

Claim-checked evidence for building an ROI model, with universal payback claims excluded.

Equipment Downtime Cost Statistics

Scoped downtime costs, unplanned work and prevention evidence, plus explicit checks on unsupported claims.

Maintenance KPI Benchmarks

Source-reviewed benchmarks on wrench time, planned versus reactive work, downtime and Australian machinery safety.

Safety & Compliance Statistics

Current WHS penalties, workplace fatalities and injury costs, with unsupported inspection and ROI claims withdrawn.

Citation Centre

Publisher-ready stats, charts, calculator embeds, and template previews for articles and resource guides.

WHS Enforcement & Penalties 2026

24 cited stats on Australian worker fatalities, prosecutions, fines, penalties by state, and industrial manslaughter.

Market & Adoption Trends

4 source-reviewed stats on QR and barcode adoption, spreadsheet use, GPS fleet tracking and RFID forecasts.

Theft & LossDowntime CostsMaintenanceCompliance & SafetyAdoption & TrendsROI & Savings

Theft & Loss

Statistics on equipment theft, tool loss, and asset shrinkage across industries.

£40 million

UK tool theft cost tradespeople £40m in 2024

Direct Line estimated £40 million of tools were stolen in 2024 by multiplying a £1,565.02 survey average by 25,525 police-reported cases with usable data from 29 of 45 UK forces.

Direct Line for Business compiled police-reported tool theft cases across UK forces. The count covers reported cases and usable data from 29 of 45 forces, so it is an insurer compilation rather than an official national measurement.

Source: Direct Line for Business () · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#theft-uk-tool-value-2024

66%

Two thirds of UK tradespeople have had tools stolen

Two thirds of UK tradespeople have been victims of tool theft, losing an average of £1,119 of tools per incident.

Censuswide surveyed 500 UK tradespeople for insurer Markel between 23 and 26 June 2025. Self-reported lifetime victimisation, not an annual rate, and the £1,119 average is per incident rather than per victim.

Source: Markel UK, Tools Down: The impact of tool theft on UK trades () · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#theft-uk-tradesperson-share

£41.5 million

UK rural crime cost £41.5m in 2025

Rural crime across the UK, spanning farm machinery, vehicle and livestock theft, cost an estimated £41.5 million in 2025, down 6% on 2024.

NFU Mutual estimates from its own claims data, which covers roughly three quarters of the UK farming market. Claims-based, so it excludes uninsured losses and anything below policy excess.

Source: NFU Mutual, Rural Crime Report 2026 () · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#theft-uk-rural-crime-annual

US$300 million–$1 billion

Annual construction equipment theft in the US

The joint NER and NICB 2016 report estimated US construction-equipment machine theft at US$300 million to US$1 billion a year. It excludes tools, materials and indirect costs and is not a current annual total.

The estimate covers machines only. NER excludes stolen tools and building materials, damage caused during a theft, and business-interruption losses such as rentals, project-delay penalties and wasted crew time, so the amount a contractor actually carries is higher.

Source: National Equipment Register & National Insurance Crime Bureau, 2016 Equipment Theft Report (p.16) () · archived copy · source reviewed, not independently verified

The 2016 report is the most recent public NER/NICB edition we found.

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#theft-ner-annual

21%

Recovery rate for stolen construction equipment

The joint NER and NICB 2016 report recorded 2,442 recoveries from 11,574 construction-equipment theft reports in the NCIC active file, or 21% for that year. It is not a lifetime recovery rate.

The NICB logged 11,574 reports of stolen machines in 2016 against 2,442 recoveries in the NCIC active theft file. The rate understates the problem: it counts neither machines that law enforcement recovered but never marked as recovered, nor thefts that were never reported.

Source: National Equipment Register & National Insurance Crime Bureau, 2016 Equipment Theft Report (p.17) () · archived copy · source reviewed, not independently verified

The 2016 report is the most recent public NER/NICB edition we found.

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#theft-recovery-rate

No source found

The viral 1 in 3 projects delayed by theft claim could not be verified

Our source review found no published evidence that 1 in 3 construction projects are delayed by theft or missing equipment.

The nearest verified data, the CIOB crime survey, found that 21% of UK professionals saw site theft weekly, but project delays were never quantified. The claim circulates uncited in vendor blogs and AI answers, often credited to a 2016 CIOB survey. The report is actually from 2009 - the 2016 in its file path is a website upload date.

Unverified claim check. Do not cite this as a measured finding.

Source: Chartered Institute of Building, Crime in the Construction Industry (2009) () · claim not verified

The publisher URL was unavailable when checked on 15 August 2026; the archived copy preserves the 2009 report.

Citation and embed tools are disabled until this claim is verified against a primary measurement.

70% of loader thefts

Skid steers lead thefts within the loader category

Within loader thefts recorded by NER and NICB, skid steers account for 70%, backhoes 22% and wheel loaders 8%.

Scope matters: loaders represent 18% of all 11,574 theft reports, while mowers and riding or garden tractors lead the full equipment table at 41%. NER groups front-end, tracked, wheeled, skid steer and backhoe machines in one loader category. The raw counts of 409 skid steers and 182 backhoes appear in a separate recovery table and must not be described as theft counts.

Source: National Equipment Register & National Insurance Crime Bureau, 2016 Equipment Theft Report (p.9) () · archived copy · claim checked against source

The 2016 report is the most recent public NER/NICB edition we found; NER appears to have stopped publishing after it.

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#theft-backhoe-top

71.6%

Assets logged more than 30 days after they were received

A 2006 GAO audit found 71.6% of CSC-purchased FBI Trilogy IT items recorded in PMA were entered more than 30 days after receipt; CSC purchases represented about 52% of Trilogy assets.

Source: US Government Accountability Office, GAO-06-306 () · archived copy · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#asset-register-late-registration

-72%

Theft from vehicles in NSW fell 72% in a generation

Recorded thefts from motor vehicles in New South Wales fell from 90,528 in 2001 to 25,218 in 2025, a 72% decline over 24 years.

MapTrack independently reproduced the annual totals and rounded change from a frozen, checksummed subset of the 18 June 2026 NSW Bureau of Crime Statistics and Research workbook. Recorded crime counts incidents reported to police, so it understates true volume, and the trend is NSW only. The source extract, metadata and deterministic generator are published with the MapTrack Equipment Theft Index.

Source: NSW Bureau of Crime Statistics and Research () · claim checked against source

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#theft-nsw-from-vehicle-decline

-85%

NSW non-residential break-ins fell 85% since 2001

Break and enter offences at non-residential premises in New South Wales fell from 52,203 in 2001 to 7,639 in 2025.

MapTrack independently reproduced the annual totals and rounded change from a frozen, checksummed subset of the 18 June 2026 NSW Bureau of Crime Statistics and Research workbook. Break and enter non-dwelling includes worksites, yards and workshops but covers all non-residential premises, so it is a broad proxy rather than a direct construction-theft measure.

Source: NSW Bureau of Crime Statistics and Research () · claim checked against source

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#theft-nsw-worksite-breakin-decline

+42%

NSW vehicle theft has risen 42% since 2021

Motor vehicle theft in New South Wales rose from 10,496 incidents in 2021 to 14,857 in 2025, a 42% increase, while theft from vehicles fell 9% over the same period.

MapTrack independently reproduced both annual totals and the rounded change from a frozen, checksummed subset of the 18 June 2026 NSW Bureau of Crime Statistics and Research workbook. Motor vehicle theft and theft from motor vehicles are separate police-recorded offence categories, and both remain below their 2001 levels.

Source: NSW Bureau of Crime Statistics and Research () · claim checked against source

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#theft-nsw-vehicle-theft-reversal

69 a day

NSW records about 69 thefts from vehicles every day

New South Wales recorded 25,054 thefts from motor vehicles in the twelve months to March 2026, an average of about 69 a day.

MapTrack independently reproduced the 25,054 rolling-twelve-month total from a frozen, checksummed subset of the 18 June 2026 NSW Bureau of Crime Statistics and Research workbook. Dividing by 365 gives 68.64, rounded to 69. The count is police-recorded incidents in one state, not a national tool-theft estimate.

Source: NSW Bureau of Crime Statistics and Research () · claim checked against source

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#theft-nsw-from-vehicle-daily-rate

$40.8 million

Tools stolen from Victorian tradies in a single year

RACV reported Crime Statistics Agency data showing 36,708 hand and power tools worth $40.8 million stolen from Victorian vehicles and worksites in the year to 30 June 2025, up 7.5% year on year.

Source: RACV, citing the Crime Statistics Agency (Victoria) () · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#theft-vic-tradie-tools

US$725 million per year

Annual cargo theft losses across the United States and Canada

Verisk CargoNet estimated nearly US$725 million in cargo-theft losses from incidents reported to its proprietary United States and Canada database in 2025, up 60% year on year.

Verisk CargoNet annual analysis of incidents reported to its national database: 3,594 supply chain crime events in 2025 against 3,607 in 2024, with confirmed cargo thefts up 18% to 2,646. Reported incidents are a floor on the true total. CargoNet attributes the loss surge to organised groups targeting higher-value shipments.

Source: Verisk CargoNet () · archived copy · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#cargo-theft-annual-losses

US$273,990 per theft

Average value of a single cargo theft

Among confirmed cargo-theft incidents reported to Verisk CargoNet in the United States and Canada, average value rose 36% to US$273,990 in 2025 from US$202,364 in 2024.

Verisk CargoNet annual analysis, averaged across confirmed cargo theft incidents reported to CargoNet in the United States and Canada. The rise reflects target selection, not more incidents: confirmed thefts rose 18% while total supply chain crime events were flat.

Source: Verisk CargoNet () · archived copy · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#cargo-theft-average-value

Only ~5%

Recovery rate for tools stolen across Queensland

Queensland Police recorded more than 25,000 tools stolen in the 2024-25 financial year, but only 1,283 were returned to their owners, a recovery rate of roughly 5%.

Source: Queensland Police Service () · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#theft-qld-tools-recovery

Downtime Costs

The financial impact of unplanned equipment downtime and asset unavailability.

US$131 a day

What an idle 20-tonne excavator costs to own

A 20-tonne-class excavator that is broken down or standing idle still costs about US$16.39 an hour to own, or US$131 over an eight-hour day, before repairs, operator wages, a replacement machine or any delay penalty.

MapTrack calculation from the California Department of Transportation's Labor Surcharge and Equipment Rental Rates, effective 1 April 2026 to 31 March 2027: the hourly rate for a Caterpillar 320 (code 0310, US$96.41, printed page 9) multiplied by the delay factor for crawler-mounted hydraulic cranes and excavators (0.17, printed page 8), then by eight hours. Caltrans may pay idle equipment on an excusable delay at this ownership-only rate, with the resident engineer's approval, excluding operating costs such as fuel and repairs, for at most eight hours a day. These are California rates for owned equipment. They exclude the operator, and Caltrans notes its calculated rates are likely lower than a rental yard would charge.

Source: California Department of Transportation (Caltrans), Labor Surcharge and Equipment Rental Rates, 1 April 2026 to 31 March 2027 () · claim checked against source

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#downtime-idle-excavator-ownership-2026

US$61 to US$228 a day

Idle ownership cost across common construction machines

Common construction machines cost about US$61 to US$228 a day to own while idle: US$61 for a compact track loader, US$131 for a 20-tonne excavator, US$153 for a motor grader, US$176 for a mid-size wheel loader and US$228 for a 30-tonne excavator.

MapTrack calculation: eight hours at each machine's Caltrans ownership-only delay rate (hourly rental rate multiplied by its class delay factor), effective 1 April 2026 to 31 March 2027. Caterpillar 299D2 compact track loader US$69.60 x 0.11; Caterpillar 320 excavator US$96.41 x 0.17; Caterpillar 140M motor grader US$174.32 x 0.11; Caterpillar 950M wheel loader US$199.62 x 0.11; Caterpillar 330L excavator US$167.61 x 0.17. California rates for owned equipment, excluding the operator.

Source: California Department of Transportation (Caltrans), Labor Surcharge and Equipment Rental Rates, 1 April 2026 to 31 March 2027 () · claim checked against source

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#downtime-idle-ownership-range-2026

US$96.41 an hour

What a working 20-tonne excavator costs per hour

A 20-tonne-class excavator costs US$96.41 an hour to own and operate before the operator's wage, under California's 2026-27 equipment rate for a Caterpillar 320.

Caltrans rental rate for a Caterpillar 320 (code 0310, crawler-mounted hydraulic cranes and excavators, printed page 9), effective 1 April 2026 to 31 March 2027. It covers fuel, oil, lubrication, repairs and maintenance, depreciation, storage, cost of facilities capital, overhaul and incidentals, and the labour to provide them. It excludes the operator and the 15% overhead markup Caltrans adds on force-account work. Caltrans notes this calculated rate is likely lower than a rental yard's, which can include profit and a short-term premium.

Source: California Department of Transportation (Caltrans), Labor Surcharge and Equipment Rental Rates, 1 April 2026 to 31 March 2027 () · claim checked against source

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#downtime-excavator-operating-rate-2026

US$28.66 an hour

Median wage of a US construction equipment operator

US construction equipment operators earned a median US$28.66 an hour, or US$59,600 a year, in May 2025, so a paid eight-hour wait beside a stopped machine costs about US$229 in wages alone.

US Bureau of Labor Statistics, Occupational Outlook Handbook, Construction Equipment Operators, Quick Facts and Pay, May 2025 wages: median US$28.66 an hour and US$59,600 a year for the occupation group. Its largest sub-group, operating engineers and other construction equipment operators (47-2073), earned a median US$59,850 a year (OEWS May 2025: US$28.78 an hour, mean US$31.87, 478,090 employed). US$229 is eight hours at US$28.66 (US$229.28). Wages exclude employer payroll taxes, insurance and benefits, so the full cost of paid standby time is higher.

Source: US Bureau of Labor Statistics, Occupational Outlook Handbook: Construction Equipment Operators (May 2025 wages) () · claim checked against source

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#downtime-operator-wage-us-2025

US$3,498 a day

Late-completion charge on a US$5 million to under US$10 million road contract

Florida's transportation department charges US$3,498 for every calendar day a US$5 million to under US$10 million road contract finishes late, and US$11,171 a day plus 0.005% of the excess on contracts of US$40 million or more.

Florida Department of Transportation, Standard Specifications for Road and Bridge Construction, FY 2026-27, section 8-10.2 (printed page 101). The schedule rises from US$1,318 a day for contracts under US$300,000 through US$6,703 a day for US$20 million to under US$40 million, to US$11,171 a day plus 0.005% of the excess at US$40 million or more. Default days are counted in calendar days (8-10.3). One state schedule, not a national average.

Source: Florida Department of Transportation, Standard Specifications for Road and Bridge Construction, FY 2026-27, section 8-10.2 () · claim checked against source

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#downtime-liquidated-damages-fdot-2026

US$90.78 per hour

Marginal cost of running a truck per hour

ATRI estimated US motor carriers' average marginal operating cost at US$90.78 per hour in 2022. It is a carrier operating-cost measure, not a measured standing-idle cost.

ATRI collects operational cost data directly from motor carriers each year. Marginal cost covers fuel, repair and maintenance, truck and trailer payments, insurance, permits, tolls and driver pay and benefits. It excludes fixed overhead, so it is the cost that stops accruing value when the vehicle is not moving.

Source: American Transportation Research Institute, Analysis of the Operational Costs of Trucking: 2023 Update () · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#downtime-truck-marginal-cost-hour

1 hour 46 minutes

Average truck dwell time per stop

US trucks spent an average of 1 hour 46 minutes waiting at each shipper or receiver stop in 2022 before they could load or unload.

ATRI industry average across carriers surveyed for its annual operational cost study. Dwell is measured waiting time at a shipper or receiver; the report does not establish the revenue effect for an individual carrier.

Source: American Transportation Research Institute, Analysis of the Operational Costs of Trucking: 2023 Update () · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#downtime-truck-dwell-time

US$2.336 per mile

Industry-average cost of operating a truck

The industry-average cost to operate a truck reached US$2.336 per mile in 2025, up 3.4% on the year before and the highest per-mile cost in the history of ATRI’s operational cost survey.

ATRI Analysis of the Operational Costs of Trucking, 2026 Update (2025 is the most recent surveyed year). Excluding fuel, costs rose 4.2% to US$1.854 per mile. ATRI collects this data directly from motor carriers each year.

Source: American Transportation Research Institute () · archived copy · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#trucking-operating-cost-per-mile

Misattributed

The $50 billion unplanned downtime figure is not a Deloitte measurement

The most-quoted downtime figure in industrial maintenance is credited to Deloitte, but Deloitte relayed it from a WSJ Custom Content page that cites no survey or method.

The origin is IndustryWeek in collaboration with Emerson. Deloitte Insights, Industry 4.0 and predictive technologies for asset maintenance (9 May 2017), carries the sentence at endnote 2, accessed 7 March 2017. That endnote points to a page on the WSJ partner network labelled PAID PROGRAM and "created by Custom Content from WSJ, a unit of The Wall Street Journal Advertising Department", produced by IndustryWeek in collaboration with Emerson, which sells reliability and automation services. The page asserts the figure and cites nothing for it. Quote it as a vendor estimate relayed by Deloitte in 2017, not as Deloitte research, and not as a current number.

Unverified claim check. Do not cite this as a measured finding.

Source: IndustryWeek in collaboration with Emerson, How manufacturers can achieve Top Quartile performance, WSJ Custom Content () · archived copy · claim not verified

The origin page carries no publication date. Deloitte recorded accessing it on 7 March 2017, which is the earliest date the figure can be placed.

Citation and embed tools are disabled until this claim is verified against a primary measurement.

Same unsourced origin

The 42% of downtime caused by equipment failure claim shares that origin

The companion figure, that equipment failure causes 42% of unplanned downtime, appears in the same sentence pair on the same WSJ Custom Content page, with the same absence of any survey, sample or method.

Both numbers travel together through vendor blogs and AI answers, and both inherit the same provenance problem. Our review found no primary measurement behind either. If you have found a study that measured the 42% split, contact us and we will verify and cite it.

Unverified claim check. Do not cite this as a measured finding.

Source: IndustryWeek in collaboration with Emerson, How manufacturers can achieve Top Quartile performance, WSJ Custom Content () · archived copy · claim not verified

The origin page carries no publication date; 2017 is the earliest date the figure can be placed, from Deloitte recording access on 7 March 2017.

Citation and embed tools are disabled until this claim is verified against a primary measurement.

US$36,000–$2.3m per hour

Cost of an hour of unplanned downtime in industry

A Siemens and Senseye 2024 vendor study of mainly large manufacturers estimated an unproductive hour at about US$36,000 in fast-moving consumer goods and US$2.3 million in a large automotive plant.

Scope: Siemens and Senseye surveyed mainly large manufacturers and major heavy-industry producers worldwide across automotive, heavy industry, FMCG, oil and gas and pharmaceuticals. The US$36,000 FMCG floor and US$2.3 million automotive ceiling appear on report pages 2-4; the report separately says SME losses can reach US$150,000 an hour at the top end on page 7. Sector sample mix varied between years, so the combined trend is indicative. Across the sectors surveyed, unplanned downtime costs an average large plant US$253 million a year.

Source: Siemens / Senseye, The True Cost of Downtime 2024 () · archived copy · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#downtime-cost-manufacturing

No primary source found

The $2,000–$10,000 construction downtime range is unverified

Our review found no Construction Industry Institute publication supporting this widely repeated daily cost range.

The range circulates widely credited to the Construction Industry Institute, but on 2026-09-05 we could not find it in any CII publication: the knowledge base returned no equipment-downtime title, and a site-restricted search surfaced only safety, productivity, rework and zero-injury-economics research. Searching the open web for the figure returns our own page. Do not use the range as a measured finding unless a primary document is produced.

Unverified claim check. Do not cite this as a measured finding.

Source: Widely attributed to the Construction Industry Institute; attribution not verified () · claim not verified

No underlying study or date has been located, so the 2024 year is the vintage of the secondary sources repeating it rather than of any measurement.

Citation and embed tools are disabled until this claim is verified against a primary measurement.

up to 30–40%

Cost opportunity of moving off reactive-heavy maintenance

A 2010 US Department of Energy guide synthesising older facility evidence reported a possible 30-40% predictive-maintenance opportunity versus reactive-heavy operations and 12-18% for preventive maintenance. These are historical guide estimates, not current software outcomes.

Scope: US Department of Energy / PNNL O&M Best Practices Guide, Release 3.0, section 5.3 on preventive maintenance and section 5.4 on predictive maintenance, PDF pages 51-52. The guide reports 12-18% preventive-over-reactive savings, 8-12% predictive-over-preventive savings and opportunities exceeding 30-40% where a facility relies heavily on reactive maintenance.

Source: US Department of Energy / PNNL, O&M Best Practices Guide () · archived copy · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#downtime-reactive-cost

11%

Annual revenue lost to unplanned downtime

A Siemens and Senseye 2024 vendor study estimated unplanned downtime at about 11% of combined revenue for the Fortune Global 500, or almost US$1.4 trillion a year.

Scope: Siemens / Senseye, The True Cost of Downtime 2024, executive summary on report pages 2-3. This is an estimate for the world's 500 largest companies by revenue, not a benchmark for a typical plant or smaller business.

Source: Siemens / Senseye, The True Cost of Downtime 2024 () · archived copy · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#downtime-lost-revenue

6 billion gallons per year

Fuel wasted through unnecessary vehicle idling

Argonne National Laboratory estimates that unnecessary idling across all US road vehicles wastes more than 6 billion gallons of fuel and more than US$11 billion each year, using a conservative US$2-per-gallon valuation.

Argonne National Laboratory estimate spanning all US road vehicles, passenger cars through heavy-duty trucks; long-haul trucks alone burn more than 1 billion gallons idling during required rest stops. The US$11 billion valuation is the source’s own conservative floor at US$2 per gallon. An earlier version of this entry carried a higher fleet-operator dollar figure the cited source does not state; see the superseded-figures register.

Source: US Department of Energy, Argonne National Laboratory () · archived copy · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#fleet-idle-fuel-waste

US$108.8 billion per year

Annual cost of traffic congestion to the US trucking industry

Traffic congestion on US highways added US$108.8 billion in operational costs to the trucking industry in 2022, a record high and a 15.0% increase year on year.

ATRI Cost of Congestion 2024 Update (published December 2024; 2022 is the most recent modelled year), computed from ATRI’s truck GPS database and operational-cost benchmarks. Total congestion hours fell slightly from 2021 in a softening freight market, but per-truck operating costs rose faster, so the dollar cost still climbed.

Source: American Transportation Research Institute () · archived copy · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#trucking-congestion-annual-cost

US$7,588 per truck per year

Average congestion cost for every registered combination truck

Highway congestion cost an average of US$7,588 for every registered combination truck in the United States in 2022, with total industry delay equivalent to more than 430,000 drivers sitting idle for a full working year.

ATRI Cost of Congestion 2024 Update; the per-truck average divides the US$108.8 billion national congestion cost across registered combination trucks. 2022 is the most recent modelled year.

Source: American Transportation Research Institute () · archived copy · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#trucking-congestion-per-truck-cost

6.4 billion gallons of diesel

Diesel wasted each year by US trucks stuck in congestion

The US trucking industry wasted more than 6.4 billion gallons of diesel fuel sitting in congestion in 2022, adding US$32.1 billion in fuel costs alone.

ATRI Cost of Congestion 2024 Update. Distinct from the Argonne idling figure: this measures fuel burned in congested traffic by trucks specifically, not fuel lost to discretionary idling across all road vehicles.

Source: American Transportation Research Institute () · archived copy · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#trucking-congestion-fuel-waste

~$1.4 trillion

Annual cost of unplanned downtime to the 500 largest companies

A Siemens and Senseye vendor study estimated that unplanned downtime costs the world’s 500 largest companies by revenue almost US$1.4 trillion a year, about 11% of their combined revenue.

Scope: Siemens / Senseye, The True Cost of Downtime 2024, executive summary on report pages 2-3. This is an estimate for the world's 500 largest companies by revenue and should not be generalised to a typical plant or smaller business.

Source: Siemens / Senseye, The True Cost of Downtime 2024 () · archived copy · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#downtime-fortune500-annual

27 hours a month

Production time an average large plant loses to unplanned downtime

A Siemens and Senseye vendor study, covering mainly large manufacturers and heavy-industry producers, reported an average of about 27 unplanned-downtime hours and 25 incidents per facility per month.

Scope: Siemens / Senseye, The True Cost of Downtime 2024, executive summary on report page 3. The survey mainly covers large manufacturers and major heavy-industry producers; 27 hours and 25 incidents are monthly averages per facility across the sectors surveyed.

Source: Siemens / Senseye, The True Cost of Downtime 2024 () · archived copy · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#downtime-plant-monthly-hours

40-50%

Vendor-survey estimate of underutilised fleet equipment

Respondents to Teletrac Navman’s 2026 vendor survey estimated that 40 to 50% of their equipment was underutilised or unused; 67% reported assets held onsite but unused at least some of the time.

Source: Teletrac Navman, 2026 Equipment Utilization Report (via Construction Equipment) () · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#downtime-fleet-underutilised

$2.3 million

Cost of one unproductive hour in automotive manufacturing

A Siemens and Senseye vendor study estimated an unproductive hour at a large automotive plant at US$2.3 million. It reported about US$36,000 per hour for fast-moving consumer goods; these figures should not be generalised beyond the surveyed large manufacturers.

Scope: Siemens / Senseye, The True Cost of Downtime 2024, report pages 2-4. The US$2.3 million figure describes an unproductive hour at a large automotive plant; the US$36,000 floor describes FMCG. The survey mainly covers large manufacturers and major heavy-industry producers.

Source: Siemens / Senseye, The True Cost of Downtime 2024 () · archived copy · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#downtime-automotive-hourly-2024

~US$125,000

Respondent estimate of hourly industrial downtime cost

In an ABB-commissioned Sapio Research survey of 3,215 plant-maintenance decision-makers, respondents estimated unplanned-downtime cost at close to US$125,000 per hour.

Source: ABB, Value of Reliability survey (Sapio Research) () · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#downtime-abb-hourly

2 in 3

Monthly outage frequency in an ABB-commissioned survey

In an ABB-commissioned Sapio Research survey of 3,215 plant-maintenance decision-makers, more than two-thirds reported unplanned outages at least monthly and 21% reported relying on run-to-fail maintenance.

Source: ABB, Value of Reliability survey (Sapio Research) () · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#abb-outage-frequency

Maintenance

Benchmarks for preventive maintenance, CMMS adoption, and maintenance spending.

US$22 billion (83%)

Deferred maintenance backlogs grew 83% in five years

Deferred maintenance and repair backlogs at four US federal agencies grew by about US$22 billion, or 83%, across the five years to FY2022.

GAO reviewed four selected agencies, so the figure is not a whole-of-government total. Deferred maintenance is work identified and then not funded in the year it fell due: the backlog compounds because deferral raises the eventual cost of the same repair.

Source: US Government Accountability Office, GAO-24-105485, Deferred Maintenance and Repair () · archived copy · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#maintenance-deferred-backlog-us-federal

£49 billion

UK public facilities carry a £49bn maintenance backlog

The UK government has accumulated at least £49 billion of deferred maintenance backlog across public service facilities.

National Audit Office figure, January 2025, covering schools, hospitals, courts, prisons and defence estates. Stated as a floor rather than a point estimate: the NAO notes government does not hold complete condition data for parts of the estate.

Source: UK National Audit Office, Maintaining public service facilities () · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#maintenance-deferred-backlog-uk

US$5.19 per square foot

Australian facility maintenance costs run double Asia

An IFMA 2022 association benchmark reported US$5.19 per square foot for Australia and Singapore combined, against US$2.50 across its Asia dataset.

IFMA operations and maintenance benchmarking, covering external and interior maintenance, roads and grounds, central systems and process treatment. Reported in US dollars per square foot for comparability across markets.

Source: International Facility Management Association, Asia Operations and Maintenance Benchmarking Report () · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#maintenance-facility-cost-per-sqft-au

+8.6% in one year

Annual rise in truck repair and maintenance costs

ATRI's 2026 survey of US motor carriers reported repair and maintenance costs rose 8.6% in 2025. The survey does not establish a single cause for the increase.

ATRI Analysis of the Operational Costs of Trucking, 2026 Update. Repair and maintenance sat alongside tolls (+13.2%), driver benefits (+6.6%) and tyres (+6.4%) as the fastest-growing line items in 2025; only fuel and driver pay rose at sub-inflationary rates.

Source: American Transportation Research Institute () · archived copy · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#truck-repair-maintenance-inflation

9%

Faulty workmanship and maintenance is the third top cause of corporate insurance loss

An Allianz analysis of 534,456 corporate insurance claims found that faulty workmanship and maintenance incidents are the third largest cause of loss by value, accounting for 9% of claims value and 7% of claims by number.

Scope: Allianz Global Corporate & Specialty, Global Claims Review 2022, PDF page 5, with the dataset described on PDF page 2. Based on 534,456 corporate insurance claims from 207 countries and territories between 1 January 2017 and 31 December 2021, worth approximately EUR 88.7bn. Allianz groups faulty workmanship together with maintenance in one cause-of-loss category, and gives collapse or subsidence from faulty work, faulty manufacturing of products and components, and incorrect design as its examples, so the 9% is not attributable to maintenance failure alone. Claim values are 100% of each loss rather than only the Allianz share. Regional tables in the same report show different shares, so 9% is specifically the global figure.

Source: Allianz Global Corporate & Specialty, Global Claims Review 2022 () · archived copy · source reviewed, not independently verified

Published in July 2022 and based on claims from 1 January 2017 to 31 December 2021. Treat this as a historical five-year claims window, not a current-year loss forecast.

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#insured-loss-faulty-workmanship-maintenance

12–18%

Cost savings from preventive vs reactive maintenance

A 2010 US Department of Energy guide synthesising older facility evidence reported an estimated 12% to 18% preventive-maintenance saving over reactive work. It is not a guaranteed software outcome.

The US Department of Energy adds that facilities relying purely on reactive maintenance "could save much more than 18% by instituting a proper preventive maintenance program", and that moving on from preventive to predictive maintenance saves a further 8% to 12%.

Source: US Department of Energy, Federal Energy Management Program, O&M Best Practices Guide Release 3.0 (p.5.3) () · archived copy · source reviewed, not independently verified

Release 3.0 (August 2010) is the current edition of the DOE guide; no later release has been published.

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#pm-savings

46.3%

Share of fleet maintenance work that is unplanned

Fleetio vendor-platform data, reported by FleetOwner, covered roughly 1.2 million assets and 8.85 million work orders. It classified 53.7% of vehicle maintenance as scheduled, 40.1% as unscheduled and 6.2% as emergency, so unplanned work represented 46.3%.

Source: FleetOwner, reporting Fleetio benchmark data () · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#fleet-unplanned-maintenance-ratio

35% → 55%

Modelled wrench-time target in maintenance-planning guidance

Maintenance-planning author Doc Palmer uses 35% average wrench time and a 55% planned-and-scheduled target to model a 57% productivity gain. This is practitioner guidance and arithmetic, not a measured causal study.

Source: Doc Palmer CMRP, in Plant Services () · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#wrench-time-planning-gain

> 55%

Reactive share in a historical US maintenance benchmark

A 2010 US Department of Energy guide reproduced circa-2000 facility evidence in which more than 55% of maintenance resources and activities were reactive, 31% preventive and 12% predictive. It is not a current prevalence estimate.

Scope: US Department of Energy / PNNL O&M Best Practices Guide, Release 3.0, section 5.2, PDF page 50. The mix reproduces a study described by the guide as recent in winter 2000, so it is a historical US facility benchmark rather than a current global prevalence estimate.

Source: US Department of Energy / PNNL, O&M Best Practices Guide () · archived copy · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#reactive-share-average

~80%

Proactive-hours target relayed in a PEMAC workshop

PEMAC workshop slides relaying purported SMRP best-practice targets allocate 15% of hours to preventive work, 15% to PM-generated corrective work, 15% to predictive work and 35% to PdM-generated corrective work. The roughly 80% total is MapTrack arithmetic.

Source: SMRP Best Practices Committee (via PEMAC workshop) () · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#smrp-proactive-hours-target

1.0 / 2.5 hrs

PM and PdM yield targets relayed in a PEMAC workshop

PEMAC workshop slides relaying purported SMRP best-practice targets show about 1 hour of corrective work per preventive-maintenance hour and 2.5 hours per predictive-maintenance hour. Treat these as workshop targets, not measured averages.

Source: SMRP Best Practices Committee (via PEMAC workshop) () · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#smrp-pm-pdm-yield

10× ROI

Historical survey ranges for predictive-maintenance programs

A 2010 US Department of Energy guide synthesising older industry surveys reported ranges including 10 times ROI, 25-30% lower maintenance costs, 70-75% fewer breakdowns, 35-45% less downtime and 20-25% more production. These are historical survey ranges, not guaranteed current outcomes.

Scope: US Department of Energy / PNNL O&M Best Practices Guide, Release 3.0, section 5.4, PDF pages 51-52. The guide attributes these industrial-average results to independent surveys and warns that predictive maintenance requires material diagnostic-equipment, training and program-development investment.

Source: US Department of Energy / PNNL, O&M Best Practices Guide () · archived copy · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#doe-pdm-program-results

13.0% vs 4.0%

NIST US manufacturing downtime: most- and least-reactive groups

NIST's historical US manufacturing survey: most-reactive quartile downtime 13.0% of planned production time; least-reactive 4.0%. Small-group association, not causal savings; many group differences weren't statistically significant.

NIST AMS 100-34 (June 2020), section 7.1 and Table 7.2, printed pages 35-36. The Machinery Maintenance Survey covers US discrete manufacturing (NAICS 321-339, excluding 324 and 325). Groups are the top and bottom quarters by reliance on reactive maintenance; these are averages of survey responses. This association does not establish the saving from changing a maintenance programme, or a benchmark for construction equipment.

Source: NIST, Economics of Manufacturing Machinery Maintenance () · source reviewed, not independently verified

Published in 2020. Historical survey evidence, not a 2026 benchmark; the source-review date is not the measurement year.

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#nist-reactive-maintenance-downtime

US$222 billion a year

Total annual cost of maintenance to US discrete manufacturers

Maintenance costs US discrete manufacturers about US$222 billion a year once direct maintenance spending is counted alongside the losses that follow from faults, unplanned downtime, defects and lost sales.

Scope: NIST Machinery Maintenance Survey (Thomas and Weiss), published in the International Journal of Prognostics and Health Management. Mean estimate US$222.0 billion, median US$211.8 billion, in 2016 dollars. It is a total cost of maintenance, NOT a figure for waste: the components are direct maintenance US$81.6bn, lost sales US$105.0bn, unplanned downtime US$18.4bn, additional cost of faults and failures US$15.7bn, inventory US$0.8bn and defects US$0.5bn. Survey base is 71 usable responses from 85 received. US discrete manufacturing only (NAICS 321-339, excluding 324 and 325).

Source: NIST (Thomas and Weiss), International Journal of Prognostics and Health Management () · archived copy · source reviewed, not independently verified

MapTrack’s August 2026 source review found no newer equivalent NIST survey, so this 2016 baseline is the latest NIST estimate we could verify.

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#nist-maintenance-total-cost-us

52.7% less unplanned downtime

Unplanned downtime gap between predictive-led and reactive-led maintenance

Surveyed US discrete manufacturers that lean on predictive and preventive maintenance report 52.7% less unplanned downtime and 78.5% fewer defects than those that lean on reactive maintenance.

Scope: NIST Machinery Maintenance Survey (Thomas and Weiss). Respondents were split by how heavily they rely on reactive maintenance; the half relying least on it, and most on predictive and preventive, recorded the gaps above. Among that group, those weighted further toward predictive over preventive recorded a further 18.5% less unplanned downtime. Survey base is 71 usable responses from 85 received, so treat the decimal precision as an artefact of a small sample rather than a measurement guarantee. Self-reported; US discrete manufacturing only (NAICS 321-339, excluding 324 and 325).

Source: NIST (Thomas and Weiss), International Journal of Prognostics and Health Management () · archived copy · source reviewed, not independently verified

MapTrack’s August 2026 source review found no newer equivalent NIST survey, so this is the latest NIST-published comparison of maintenance strategy against downtime and defect outcomes we could verify.

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#nist-predictive-downtime-gap

545%

Calculated ROI of a structured preventive maintenance program

A Jones Lang LaSalle model for one 14-million-square-foot telecom property portfolio calculated a 545% ROI and US$2 billion NPV over 25 years for a US$39 million annual preventive-maintenance program. It used BOMA 2000 inputs and does not establish a general ROI for mobile plant.

Source: Jones Lang LaSalle (Koo & Van Hoy), archived paper () · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#jll-pm-roi-545

Compliance & Safety

Statistics on workplace safety, regulatory compliance, and inspection outcomes.

US$165,514

Maximum OSHA penalty per wilful or repeated violation

OSHA can impose up to $165,514 per wilful or repeated violation, and $16,550 for a serious violation.

Failure to abate adds up to $16,550 per day past the abatement date, generally capped at 30 days. The amounts are normally indexed to inflation each January, but the 2026 adjustment could not be made: the government shutdown stopped the Bureau of Labor Statistics publishing the October 2025 CPI-U figure the 1994 statute requires, so the 2025 levels carried over unchanged.

Source: OSHA, 2026 Annual Adjustments to OSHA Civil Penalties (effective 1 January 2026) () · archived copy · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#osha-penalty-max

AU$17.7 million

Maximum Commonwealth WHS fine for a body corporate

Under the Commonwealth WHS regime for 2026-27, a body corporate faces up to $17,728,000 for a Category 1 offence. State and territory maxima differ.

That is the Commonwealth amount for 2026-27. Category 1 also carries up to $3,546,000 for an individual who is a PCBU or an officer, and $1,773,000 for any other individual. The amounts are indexed to CPI each 1 July, which is why older figures such as the original $3 million in the 2011 model Act are now badly out of date. Each state and territory indexes its own schedule, so the exact maximum depends on the jurisdiction.

Source: Work Health and Safety (Public Notification of Indexed Penalty Amounts) Notifiable Instrument 2026 (F2026N00550) () · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#au-whs-penalty

AU$28.6 billion

Modelled annual output forgone from Australian workplace harm

A Safe Work Australia-commissioned Deloitte model estimated average annual output forgone of $28.6 billion and 185,500 full-time-equivalent jobs across 2008 to 2018 due to work-related injury and illness.

Modelled by Deloitte Access Economics for Safe Work Australia. Across 2008 to 2018 the cumulative output forgone reached $315 billion, from 6.9 million work-related injuries and illnesses. This measures economic output lost rather than premiums paid; Safe Work Australia’s separate direct-and-indirect costing put the total at $61.8 billion in 2012-13, or 4.1% of GDP.

Source: Safe Work Australia / Deloitte Access Economics, Safer, healthier, wealthier: the economic value of reducing work-related injuries and illnesses () · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#workplace-injury-cost-au

6.5%

Work-related injury rate for machinery operators and drivers

ABS data for 2021-22 recorded a 6.5% work-related injury rate among Australian machinery operators and drivers. The percentage uses people employed in that occupation as its denominator.

Source: Australian Bureau of Statistics (ABS) () · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#compliance-au-machinery-injury-rate

32%

Share of Australian worker fatalities: machinery operators and drivers

Machinery operators and drivers accounted for 32% of Australian worker fatalities in 2024 (61 of 188 deaths) with a fatality rate of 6.7 per 100,000 workers, more than five times the all-occupation rate, per Safe Work Australia Key WHS Statistics 2025.

Source: Safe Work Australia, Key WHS Statistics Australia 2025 () · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#swa-machinery-operator-fatalities

146,700

Serious workers compensation claims in Australia in a year

Safe Work Australia recorded 146,700 serious workers’ compensation claims in 2023-24 (preliminary), each involving at least one week of working time lost. Median time lost was 7.4 weeks and median compensation was $16,300.

Source: Safe Work Australia, Key WHS Statistics Australia 2025 () · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#swa-serious-claims-2024

ROI & Savings

Documented returns from implementing asset tracking and maintenance management software.

US$1.46 million

Activating existing telematics saved US$1.46m in fit-out

The US General Services Administration avoided about US$1.46 million in installation costs by switching on factory-fitted telematics already present in its leased fleet, rather than retrofitting devices.

GSA Fleet operates one of the largest civilian vehicle fleets in the world. The saving is avoided installation cost only, and does not count fuel, utilisation or maintenance effects. It is a rare telematics ROI figure published by the buyer rather than a vendor.

Source: US General Services Administration () · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#roi-telematics-activation-saving-gsa

96%

Reduction in cycle count time with RFID

Auburn University RFID Lab research cited by GS1 US reported a 96% reduction in cycle-count time for item-level RFID in a retail and supply-chain setting. The result does not quantify QR-code or barcode asset audits.

Source: Auburn University RFID Lab, via GS1 US () · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#audit-time-reduction

10-15%

Fuel-saving range in Australian eco-driving guidance

Australian National Road Safety Partnership Program guidance says changed driver behaviour can save 10 to 15% of fuel consumption. It does not attribute that range to a tracking or telematics product.

From the NRSPP Eco Driving Fact Sheet. The saving is attributed to driver behaviour - smoother acceleration, reduced idling, correct speeds - not to any monitoring product. Telematics vendors commonly restate this figure as an outcome of their own systems; the underlying research measures the driving, not the hardware.

Source: National Road Safety Partnership Program () · source reviewed, not independently verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#fleet-fuel-savings

19.4%

Reported material-cost saving in a historical CMMS survey

A 1994 A.T. Kearney and IndustryWeek survey of 558 CMMS users reported average material-cost savings of 19.4% and average payback of 14.5 months. The US Department of Energy reproduced the survey in its 2010 O&M guide.

From a survey of 558 companies using a CMMS, conducted by A.T. Kearney with Industry Week and republished by the US Department of Energy. The same respondents reported a 28.3% increase in maintenance productivity, a 20.1% reduction in equipment downtime, and a 17.8% reduction in maintenance, repair and operations inventory.

Source: US Department of Energy, O&M Best Practices Guide Release 3.0 (p.4.2), citing an A.T. Kearney and Industry Week survey of 558 CMMS users () · archived copy · source reviewed, not independently verified

The underlying survey dates from 1994 and remains the most widely cited measured set of CMMS benefits; the DOE republished it in Release 3.0 of its O&M guide in 2010.

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#maintenance-cost-reduction-cmms

Frequently asked questions

How much does construction equipment theft cost annually?

There is no current universal figure. The latest public US national report we found is the joint NER and NICB 2016 report, which estimated US$300 million to US$1 billion for stolen machines and recorded 2,442 recoveries from 11,574 theft reports. Current Australian evidence is available by state, including AU$40.8 million of tools stolen from Victorian tradespeople in the year to June 2025.

What is the average cost of unplanned equipment downtime?

In the Siemens and Senseye sample of mainly large manufacturers, an unproductive hour ranged from around US$36,000 in fast-moving consumer goods to US$2.3 million in a large automotive plant. There is no defensible universal rate. A widely repeated construction daily range remains on this page only as an explicit unverified claim check.

What does asset tracking software measurably reduce?

The strongest method-specific result in this library is a 96% cycle-count-time reduction for item-level RFID in a retail and supply-chain setting. A separate government case records one avoided installation cost. We found no independent evidence for a universal theft, utilisation or return-on-investment percentage for asset-tracking software.

How much can preventive maintenance save?

The US Department of Energy O&M guide summarises older studies indicating average savings of 12–18% for preventive maintenance over a reactive programme. Treat that as a broad facility-maintenance estimate, not a guaranteed software outcome.

How many organisations still run on spreadsheets and paper?

In a mainly US manufacturing survey, 45% of 198 respondents to a multi-select technology question named in-house spreadsheets and schedules, 39% named clipboards and paper records, and 58% named a CMMS. The survey does not establish how those methods affected visibility or performance.

How large is the asset tracking market?

Published forecasts vary by definition, geography, base year and vendor method. We withdrew the market-size figures whose linked pages did not establish the number or scope. Use only a named, current report whose exact definition and forecast window you can inspect.

Can I cite these statistics on my website?

Verified and source-reviewed entries include a citation tool and link to the source MapTrack reviewed. Unverified claim checks are labelled and do not offer citation or embed tools. Check the scope before republishing any figure.

How does GPS tracking affect insurance premiums?

It can affect an insurer’s assessment, but our review found no primary source supporting a universal percentage discount. Ask your broker or insurer for the terms that apply to your equipment, region and controls.

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