The financial impact of unplanned equipment downtime and asset unavailability.
US$90.78 per hour
Marginal cost of running a truck per hour
The average US carrier’s marginal cost of running a truck reached US$90.78 an hour in 2022, the highest in the survey’s history and the benchmark used to price a truck standing idle.
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.
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 time the vehicle and driver are committed but earning nothing, which is why it is priced against the marginal hourly cost of running the truck rather than against revenue.
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.
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.
Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#downtime-50-billion-claim-check
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.
Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#downtime-42-percent-equipment-failure-claim-check
US$36,000–$2.3m per hour
Cost of an hour of unplanned downtime in industry
An hour of unplanned downtime costs from around US$36,000 in fast-moving consumer goods to 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.
Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#downtime-cost-manufacturing
$2,000–$10,000 per day
Daily cost of equipment downtime on construction sites
When critical equipment is unavailable on a construction site, project delays can cost between $2,000 and $10,000 per day in idle labour, missed milestones, and subcontractor penalties.
Attribution unverified. This 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. Treat it as an industry rule of thumb, not a measured finding, until a primary document is produced.
Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#downtime-construction-daily
800 hours
Average annual unplanned downtime per manufacturing facility
The average manufacturing plant experiences approximately 800 hours of unplanned equipment downtime per year, equivalent to more than 15 hours per week.
Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#downtime-hours-annual
up to 30–40%
Cost opportunity of moving off reactive-heavy maintenance
US Department of Energy analysis puts the savings opportunity of a predictive program at up to 30-40% versus reactive-heavy operations, with preventive alone saving 12-18%. Emergency work carries expedited parts, overtime labour and secondary damage. The often-quoted "reactive costs 3-9x more" multiplier has no checkable primary source, so we publish the DOE percentages instead.
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.
Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#downtime-reactive-cost
11%
Annual revenue lost to unplanned downtime
Fortune Global 500 companies lose approximately 11% of their yearly revenue to unplanned downtime, amounting to nearly $1.5 trillion across those organisations.
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.
Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#downtime-lost-revenue
40%
Equipment sits idle due to poor scheduling
Construction firms report that up to 40% of their equipment fleet is idle at any given time, often because managers lack real-time visibility into availability and location.
Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#idle-equipment-waste
6 billion gallons per year
Fuel wasted through unnecessary vehicle idling
More than 6 billion gallons of fuel are lost to unnecessary idling every year across US road vehicles, worth more than US$11 billion annually even at fuel prices as low as US$2 per gallon. Telematics systems that alert managers and drivers to excessive idling are one of the most effective interventions for reducing this waste.
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.
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.
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.
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.
Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#trucking-congestion-fuel-waste
55–70%
Average fleet utilisation rate across commercial operators
Average fleet utilisation rates sit between 55 and 70%, meaning 30 to 45% of fleet capacity is idle at any given time. Best-in-class operators achieve 80 to 85% utilisation through real-time visibility, dynamic scheduling, and pooled asset sharing across projects and depots.
Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#fleet-utilisation-benchmark
$50,000–$180,000 per year
Total cost of ownership for a single commercial vehicle
Total cost of ownership for a single commercial vehicle ranges from $50,000 to $180,000 per year, encompassing fuel, insurance, maintenance, depreciation, registration, and driver costs. Without accurate tracking, fleet managers often underestimate true per-vehicle costs by 20 to 30%.
Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#fleet-tco-annual
$5,000–$10,000 per hour
Unplanned downtime cost for a large mining haul truck
Unplanned downtime for a large mining haul truck costs between $5,000 and $10,000 per hour, factoring in lost haulage capacity, idle crew wages, and contract penalties. In open-pit operations where every truck is scheduled against tight production targets, even a few hours of downtime can cascade into significant revenue loss.
Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#downtime-mining-hourly
$1,000–$5,000 per day
Average unplanned downtime cost for SMEs
Small and medium enterprises report average unplanned downtime costs of $1,000 to $5,000 per day, with 82% of affected businesses saying the impact is significant enough to warrant dedicated prevention investment. For many SMEs, a single week of equipment downtime can wipe out an entire month of profit.
Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#downtime-sme-daily
~$1.4 trillion
Annual cost of unplanned downtime to the 500 largest companies
Unplanned downtime costs the 500 biggest companies in the world almost $1.4 trillion a year, equal to about 11% of their combined revenues, based on the Siemens 2024 True Cost of Downtime study.
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.
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
The average large plant loses about 27 hours a month, more than a full day of production, to unplanned downtime across roughly 25 incidents, adding up to around 326 hours a year.
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.
Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#downtime-plant-monthly-hours
40-50%
Share of equipment fleets report as underutilised
Fleet operators estimate that 40 to 50% of their equipment is underutilised or sits unused, and 67% report assets held onsite but unused at least some of the time, per the Teletrac Navman 2026 utilisation report.
Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#downtime-fleet-underutilised
$50 billion
Annual cost of unplanned downtime to industrial manufacturers
Deloitte estimates that unplanned downtime costs industrial manufacturers around $50 billion a year, and that poor maintenance strategies can cut productive capacity by 5 to 20%.
Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#downtime-manufacturers-50b
$2.3 million
Cost of one unproductive hour in automotive manufacturing
Automotive manufacturers now lose US$2.3 million for each unproductive hour, roughly double the 2019 figure, while heavy-industry downtime costs quadrupled over the same period, per the Siemens True Cost of Downtime 2024 study. The floor of the range is about $36,000 per hour in fast-moving consumer goods.
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.
Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#downtime-automotive-hourly-2024
~US$125,000
Hourly cost of unplanned downtime for a typical industrial business
Unplanned downtime costs the typical industrial business close to US$125,000 per hour, based on an ABB Value of Reliability survey of 3,215 plant maintenance decision-makers conducted by Sapio Research in 2023.
Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#downtime-abb-hourly
2 in 3
Industrial businesses hit by unplanned outages at least monthly
Over two-thirds of industrial businesses experience unplanned outages at least once a month, and 21% still rely on run-to-fail maintenance, according to the 2023 ABB Value of Reliability survey.
Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#abb-outage-frequency