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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, on Safe Work Australia’s model law as indexed each 1 July.

MapTrack compiled the 100 figures on this page from 72 published sources. Each one is shown with the organisation that published it and the year it was published, and links to the original document.

Cited industry data on equipment theft, tool loss, downtime costs, maintenance benchmarks, compliance, and the ROI of digital asset tracking. Every statistic links to its original source. Click “Cite this statistic” to get a pre-formatted citation with a link back to this page.

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

Last updated: · 100 statistics · Free to reuse with attribution 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.

Theft & Loss

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

£40 million

UK tool theft cost tradespeople £40m in 2024

UK tradespeople had an estimated £40 million of tools stolen in 2024 across 25,525 cases reported to police, even after tool theft fell 18% on 2023.

Direct Line for Business compiled police-reported tool theft cases across UK forces. The count covers reported cases only: separate Direct Line research puts the share of victims who never report at 23%, so the true volume is higher.

Source: Direct Line for Business () · source 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 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 verified

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

90%

Nine in ten NSW farmers have experienced farm crime

Nine in ten New South Wales farmers have experienced crime on their properties, including machinery, vehicle and livestock theft, and about 30% have been targeted seven or more times.

WFI Insurance claims data combined with the University of New England Centre for Rural Criminology National Rural Crime Survey. Self-reported victimisation across all crime types, not machinery theft alone, and NSW only.

Source: WFI Insurance / University of New England Centre for Rural Criminology, National Rural Crime Survey () · source verified

Reported via insurance trade press. WFI’s own newsroom returns 403 to automated requests; the same figures appear in Beef Central and InsuranceNews.com.au coverage of the report.

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#theft-au-nsw-farm-victimisation

23%

Almost a quarter of UK tool thefts go unreported

Almost a quarter of UK tradespeople who had tools stolen never reported it to police, so published theft counts understate the real volume.

Direct Line business insurance research published April 2026, covering an estimated £35 million of tools stolen in 2025 at an average £1,300 per theft. Explains why police-reported counts are a floor rather than a measure. Cited via trade press because Direct Line Group’s own release now redirects to aviva.com after the 2025 Aviva merger, so the original release URL no longer resolves.

Source: Direct Line for Business () · source verified

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

US$300 million–$1 billion

Annual construction equipment theft in the US

Construction equipment theft costs the US industry between $300 million and $1 billion a year, with most estimates in the range of $400 million.

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 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

Only 21% of stolen construction equipment is ever recovered. Published recovery rates have consistently sat below 25%.

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 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.

Source: Chartered Institute of Building, Crime in the Construction Industry (2009) () · source verified

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

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#theft-delayed-projects-claim-check

Skid steers

Skid steers, not backhoes, lead machine theft

In the NER and NICB loader category, skid steers account for 70% of thefts against 22% for backhoes and 8% for wheel loaders, with 409 skid steers reported stolen to 182 backhoes.

NER groups front-end, tracked, wheeled, skid steer and backhoe machines in a single Loader category and splits it internally, which is where the shares come from. NER attributes the pattern to transportability rather than value: dozers and wheel loaders are worth more, but backhoes and skid steers move easily and do several jobs on site. We previously published backhoes as the most stolen type, followed by skid steers, which reverses this source.

Source: National Equipment Register & National Insurance Crime Bureau, 2016 Equipment Theft Report (p.8, p.20) () · archived copy · source verified

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 US Government Accountability Office audit found 71.6% of items were entered into the asset register more than 30 days after receipt, and 16.9% more than a year after. Delayed registration is how assets quietly fall off the books.

Source: US Government Accountability Office, GAO-06-306 () · archived copy · source 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.

Derived by MapTrack from NSW Bureau of Crime Statistics and Research recorded criminal incident data, which covers 62 offence categories monthly from January 1995. Recorded crime counts incidents reported to police, so it understates true volume, and the trend is NSW only.

Source: NSW Bureau of Crime Statistics and Research () · source verified

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

-85%

Break-ins to NSW worksites and yards fell 85% since 2001

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

Derived by MapTrack from NSW Bureau of Crime Statistics and Research recorded criminal incident data. Break and enter non-dwelling is the closest available proxy for site and yard theft: it covers all non-residential premises, so it is broader than construction alone.

Source: NSW Bureau of Crime Statistics and Research () · source verified

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.

Derived by MapTrack from NSW Bureau of Crime Statistics and Research recorded criminal incident data. The two series diverge: whole vehicles are being taken more often while the contents of vehicles are being taken less often. Both remain far below their 2001 levels.

Source: NSW Bureau of Crime Statistics and Research () · source verified

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

2.5x

Regional NSW outranks Sydney for theft from vehicles

Newcastle records 900 thefts from motor vehicles per 100,000 people against Sydney at 364, a rate 2.5 times higher. Regional centres take the top seven places statewide.

MapTrack analysis of NSW Bureau of Crime Statistics and Research LGA rankings for April 2025 to March 2026, restricted to the 49 local government areas with 50,000 or more residents. The floor matters: without it the table is topped by areas of a few thousand people, where a single incident moves the rate by more than 18 per 100,000.

Source: NSW Bureau of Crime Statistics and Research () · source verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#theft-nsw-regional-rate-vs-sydney

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.

Derived by MapTrack from NSW Bureau of Crime Statistics and Research recorded criminal incident data for April 2025 to March 2026. Counts incidents reported to police in one state only, so it is a floor rather than a national estimate.

Source: NSW Bureau of Crime Statistics and Research () · source verified

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

January

Break-ins to NSW non-residential premises peak in January

Break and enter offences at non-residential premises in New South Wales run about 19% higher in January than in September, their quietest month.

MapTrack analysis of NSW Bureau of Crime Statistics and Research monthly incident data for 2015 to 2025, indexed against the average month. January reads 112 and September 94. The seasonal swing is real but modest, and a single year should not be read as a trend.

Source: NSW Bureau of Crime Statistics and Research () · source verified

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

£800 million

Annual construction plant theft in the UK

Construction plant theft costs the United Kingdom an estimated £800 million each year, placing enormous financial pressure on contractors and driving up insurance premiums across the sector. The CESAR scheme was established to combat this through a national equipment registration and security marking programme.

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

40–60% faster

GPS tracking accelerates insurance claim resolution

Equipment owners who maintain GPS tracking data resolve insurance claims 40 to 60% faster than those without it. Location and usage logs provide immediate evidence of loss circumstances, eliminating the guesswork that typically delays investigations and payouts.

Source: National Insurance Crime Bureau () · archived copy · source verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#theft-insurance-claim-time

$40.8 million

Tools stolen from Victorian tradies in a single year

In the year to 30 June 2025, 36,708 hand and power tools worth $40.8 million were stolen from Victorian vehicles and worksites, a 7.5% rise on the year before, based on data from the Crime Statistics Agency in Victoria.

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

Estimated cargo theft losses across the United States and Canada surged 60% in a single year to nearly US$725 million in 2025, even though the overall number of supply chain crime incidents held steady.

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 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

The average value per cargo theft rose 36% in a year to US$273,990 in 2025, up from US$202,364 in 2024, as organised groups shifted from opportunistic theft to targeting extremely high-value shipments.

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 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%.

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$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.

Source: American Transportation Research Institute () · archived copy · source 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.

Source: IndustryWeek in collaboration with Emerson, How manufacturers can achieve Top Quartile performance, WSJ Custom Content () · archived copy · source 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.

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.

Source: IndustryWeek in collaboration with Emerson, How manufacturers can achieve Top Quartile performance, WSJ Custom Content () · archived copy · source 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.

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.

Source: Siemens / Senseye, The True Cost of Downtime 2024 () · archived copy · source verified

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.

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

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.

Source: US Department of Energy / PNNL, O&M Best Practices Guide () · archived copy · source verified

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.

Source: Siemens / Senseye, The True Cost of Downtime 2024 () · archived copy · source verified

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.

Source: McKinsey & Company, Construction Productivity Report () · archived copy · source verified

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.

Source: US Department of Energy, Argonne National Laboratory () · archived copy · source 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 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 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 verified

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.

Source: McKinsey Mining Operations Research () · archived copy · source verified

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.

Source: Siemens / Senseye, The True Cost of Downtime 2024 () · archived copy · source 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

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.

Source: Siemens / Senseye, The True Cost of Downtime 2024 () · archived copy · source verified

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%.

Source: Deloitte ()

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.

Source: Siemens / Senseye, The True Cost of Downtime 2024 () · archived copy · source verified

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

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.

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 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

Australia and Singapore reported facility maintenance costs of US$5.19 per square foot, against a US$2.50 average across Asia.

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.

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

Truck repair and maintenance costs rose 8.6% in 2025, one of the largest line-item increases in the industry cost survey and well ahead of inflation, as carriers ran older equipment for longer.

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 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 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 preventive maintenance program saves an estimated 12% to 18% over running equipment to failure.

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 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

50–60%

CMMS adoption rate among maintenance teams

Approximately 50–60% of maintenance-heavy organisations have adopted a CMMS or EAM system, but many still underutilise features beyond basic work order management.

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

> 90%

Best-in-class PM schedule compliance rate

Top-performing maintenance organisations achieve greater than 90% compliance with their preventive maintenance schedules. The average organisation sits at 70–80%.

Source: Reliabilityweb.com ()

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

2–4 weeks

Ideal maintenance work order backlog

A healthy maintenance organisation maintains a 2–4 week backlog of planned work. Backlogs shorter than 2 weeks indicate under-identification of work; longer than 6 weeks signal resource or scheduling issues.

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

35%

Typical wrench time in maintenance operations

Typical average wrench time is 35% of a maintenance workforce day on hands-on work, with the rest lost to travel, waiting for parts, paperwork and tool searches. Proper planning and scheduling lifts wrench time to around 55%, a 57% productivity gain, per Doc Palmer, author of the McGraw-Hill Maintenance Planning and Scheduling Handbook.

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

$0.15–$0.25 per km

Average commercial vehicle maintenance cost per kilometre

Average commercial vehicle maintenance costs range from $0.15 to $0.25 per kilometre, with reactive-only fleets paying 30 to 40% more than those with structured preventive programs. Tracking odometer readings and service intervals digitally helps fleet managers stay on the preventive side of the curve.

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

46.3%

Share of fleet maintenance work that is unplanned

Benchmark data covering roughly 1.2 million assets and 8.85 million work orders found 53.7% of vehicle maintenance was scheduled, 40.1% unscheduled and 6.2% emergency, so unplanned work accounted for 46.3% of the total. Unplanned work carries expedited parts, overtime labour and knock-on downtime.

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

12-18%

Savings from preventive maintenance over run-to-failure

US Department of Energy research finds that a preventive maintenance programme saves 12 to 18% on average versus reactive run-to-failure, while predictive maintenance can push savings beyond 30 to 40%.

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

35% → 55%

Wrench-time lift from proper planning and scheduling

Typical average wrench time for a maintenance workforce is 35% of the day on hands-on work. Proper planning and scheduling lifts it to 55%, a 57% productivity gain, equivalent to a 20-person crew doing the work of 31, according to Doc Palmer, author of the McGraw-Hill Maintenance Planning and Scheduling Handbook.

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

> 55%

Share of maintenance activity that is still reactive

More than 55% of maintenance resources and activities at an average facility are still reactive, with 31% preventive and 12% predictive, according to the US Department of Energy O&M Best Practices Guide. The guide dates from 2010 but remains the canonical public reference for the maintenance mix.

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 verified

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

~80%

Best-in-class share of maintenance hours driven proactively

SMRP best-in-class labour distribution targets put preventive maintenance at 15% of total hours, corrective work identified by PM at 15%, predictive at 15% and corrective work identified by PdM at 35%, meaning roughly 80% of hours are proactive or proactively generated.

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

1.0 / 2.5 hrs

Corrective work generated per hour of PM and PdM at top performers

On average, top performers produce about 1 hour of corrective work for each hour of preventive maintenance, and about 2.5 hours of corrective work for each hour of predictive maintenance, a public SMRP benchmark for inspection-program yield.

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

10× ROI

Average results of a functional predictive maintenance program

US Department of Energy analysis of independent industry surveys reports average results of a functional predictive maintenance program as: 10 times return on investment, 25-30% reduction in maintenance costs, 70-75% elimination of breakdowns, 35-45% reduction in downtime and 20-25% increase in production. Predictive maintenance saves 8-12% over preventive alone, and up to 30-40% versus reactive-heavy operations.

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 verified

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

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 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 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 engineering analysis of a 14-million-square-foot telecom property portfolio calculated an NPV of US$2 billion over 25 years for a $39 million per year preventive maintenance program, an ROI of 545%. The study dates from the early 2000s and covers facilities rather than mobile plant, but remains the most-cited PM ROI calculation in the literature.

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.

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

AU$17.7 million

Maximum WHS fine for an Australian body corporate

A body corporate faces up to $17,728,000 for a Category 1 work health and safety offence: reckless conduct exposing a person to a risk of death or serious injury.

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.

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

AU$28.6 billion

Annual cost of workplace injuries to the Australian economy

Australia’s economy would be $28.6 billion larger every year, with 185,500 more full-time-equivalent jobs, without 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.

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

$4–$6 return per $1

Return on workplace safety investment

OSHA research indicates that every $1 invested in workplace safety programs returns $4 to $6 in reduced injury costs, fewer workers’ compensation claims, and higher productivity.

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

50–70% reduction

Telematics-based driver behaviour programs cut harsh braking events

Telematics-based driver behaviour programs reduce harsh braking events by 50 to 70% and speeding incidents by 60 to 80%, leading to 15 to 25% fewer vehicle accidents. Real-time coaching and scorecards give drivers immediate feedback, reinforcing safer habits over time.

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

Up to AU$267,000

Maximum fine for heavy vehicle compliance breaches in Australia

Australian heavy vehicle compliance violations carry fines of up to $13,345 per offence for individual operators and up to $267,000 for body corporate breaches under the Heavy Vehicle National Law. Fatigue management, mass limits, and vehicle roadworthiness are among the most commonly enforced areas.

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#fleet-compliance-fines-au

200 fatalities

Worker fatalities recorded in Australia in 2023

Safe Work Australia recorded 200 worker fatalities in 2023, with transport, construction, and agriculture accounting for over 60% of workplace deaths. Proper equipment maintenance, pre-start inspections, and digital safety management systems are critical tools in reducing these preventable incidents.

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

$28.6 billion

Annual cost of work-related injury to the Australian economy

Work-related injuries and illnesses cost the Australian economy about $28.6 billion a year in lost output, around 1.6% of GDP, according to Deloitte Access Economics analysis commissioned by Safe Work Australia.

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

6.5%

Work-related injury rate for machinery operators and drivers

Machinery operators and drivers have one of the highest work-related injury rates in Australia at 6.5%, and being hit by moving objects or vehicles causes 11% of all work-related injuries, based on ABS data for 2021-22.

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.

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

Australian workers lodged 146,700 serious workers compensation claims in 2023-24 (preliminary), more than 400 serious claims a day, with a median 7.4 weeks of time lost and $16,300 median compensation, per Safe Work Australia Key WHS Statistics 2025.

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 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 found item-level RFID cut cycle count times by 96%, because tags are read in bulk rather than one at a time by line of sight. University of Arkansas researchers separately clocked 4,767 items an hour with RFID against 209 by barcode reader. QR and barcode scanning also speeds up counts, but we found no primary source that quantifies that separately.

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

10-15%

Eco-driving saves 10 to 15% of fuel consumption

Changing how vehicles are driven, rather than what is driven, saves 10 to 15% of fuel consumption according to the National Road Safety Partnership Program.

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 verified

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

10–20%

Insurance premium reduction with GPS tracking

Many insurers offer 10–20% premium discounts for construction and fleet operations that implement GPS tracking and real-time monitoring of high-value assets.

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#insurance-discount-gps

19.4%

Material cost savings after CMMS implementation

Companies running a CMMS report 19.4% savings in material costs, with an average payback of 14.5 months.

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 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

20–40%

Asset lifespan extension with preventive maintenance

Consistent preventive maintenance extends average asset lifespan by 20–40%, deferring capital expenditure and improving return on equipment investment.

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#asset-life-extension

28%

Labour productivity improvement with digital asset management

Construction firms implementing digital asset management and mobile work order systems report a 28% improvement in maintenance labour productivity through reduced travel time, faster parts identification, and elimination of paperwork.

Source: McKinsey Global Institute, Construction Productivity () · archived copy · source verified

Cite as: MapTrack Industry Statistics, https://www.maptrack.com/statistics#roi-labour-productivity

5–15%

Fleet fuel expenditure lost to misuse without GPS cross-referencing

Fuel card misuse and unauthorised personal use account for 5 to 15% of total fleet fuel expenditure in organisations that lack GPS cross-referencing. By matching fuel transactions against vehicle location and odometer data, fleet managers can identify anomalies and eliminate fraudulent spending.

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

Frequently asked questions

How much does construction equipment theft cost annually?

Construction equipment theft costs the US industry between $300 million and $1 billion each year according to the National Equipment Register, with fewer than 25% of stolen machines ever recovered.

What is the average cost of unplanned equipment downtime?

An hour of unplanned downtime costs from around US$36,000 in fast-moving consumer goods up to US$2.3 million in a large automotive plant. On construction sites, a single unavailable machine can cost $2,000–$10,000 per day in idle labour and missed milestones.

What does asset tracking software measurably reduce?

Published research supports effects on loss, audit time and utilisation. This library deliberately carries no headline return-on-investment figure: the ranges in wide circulation trace to vendor material rather than primary research.

How much can preventive maintenance save?

Preventive maintenance programs typically save 12–18% on total maintenance costs, and US DOE analysis puts predictive-program savings at up to 30–40% versus reactive-heavy operations.

How many organisations still run on spreadsheets and paper?

A large share. In the Plant Engineering maintenance study of 199 facilities, 45% managed maintenance on in-house spreadsheets and schedules and 39% on clipboards and paper records, against 58% using a CMMS. Facilities commonly run several of these side by side, which is how visibility gets lost.

How large is the asset tracking market?

The global asset tracking market is projected to reach $36.3 billion by 2028, growing at 13.4% CAGR, driven by IoT adoption, regulatory compliance, and supply chain visibility.

Can I cite these statistics on my website?

Yes. All statistics include their original source. Click "Cite this statistic" on any data point to get a pre-formatted citation with attribution link. We ask that you link back to this page.

How does GPS tracking affect insurance premiums?

Many insurers offer 10–20% premium discounts for operations that implement GPS tracking and real-time monitoring of high-value assets, according to the National Insurance Crime Bureau.

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