The 1:5 rule
Across multiple ATA / TMC studies, $1 of preventive work prevents $3–$7 of unplanned cost. Brake jobs especially: a $600 planned brake reline beats a $2,400 emergency brake job + tow + downtime almost every time.
Every fleet manager knows PM is cheaper than breakdowns. Few have done the math to prove it to the CFO.
Without numbers, PM budget gets cut first in lean quarters. With numbers, PM is the easiest yes in the budget meeting.
Across multiple ATA / TMC studies, $1 of preventive work prevents $3–$7 of unplanned cost. Brake jobs especially: a $600 planned brake reline beats a $2,400 emergency brake job + tow + downtime almost every time.
Three reasons: (1) PM cost is visible monthly, breakdown cost is hidden in lost revenue, (2) downtime cost isn't on the maintenance P&L, (3) breakdowns happen to 'someone else's' truck in driver-leased models. Fix the accounting and PM becomes obvious.
Run a 12-month side-by-side: PM cost + planned downtime vs unplanned repair cost + lost revenue + driver pay. Almost every fleet sees 3:1 to 7:1 ROI in favor of PM.