Tooling, Fixtures, Dies & Mold Economics worked example

Tooling Maintenance Cost at 98% on-schedule pm compliance: a worked example

This scenario runs the tooling maintenance cost calculation on the strong side: 98% on-schedule pm compliance, with every other input held at its documented default. A press shop budgets annual die upkeep to amortize it correctly across the parts each tool produces.

The inputs for this scenario

  • Scheduled PM events: 24 events (unchanged)
  • Labor & parts per PM event: 180 $/event (unchanged)
  • On-schedule PM compliance: 98 % (raised for this scenario; the documented default is 85)
  • Consumables retainer: 600 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total maintenance cost = PM events x cost per event x compliance% + consumables retainer) to the inputs above produces each figure below.
  • At this operating point the engine returns 4,834 $ for total tooling maintenance cost, the number this scenario is built around.
  • At this operating point the engine returns 201 $ / piece for tooling maintenance cost per unit.
  • At this operating point the engine returns 4,234 $ for variable tooling maintenance cost.
  • At this operating point the engine returns 600 $ for fixed tooling maintenance cost adder.

How this compares with the baseline

  • Against the tool's baseline example, where on-schedule pm compliance sits at 85% and the headline result is 4,272 $, this scenario comes in 13.15% above the baseline at 4,834 $.
  • Use it when budgeting a preventive-maintenance program for a tool set, comparing PM cost against reactive-repair history, or quantifying the cost impact of missed PM compliance. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Total tooling maintenance cost: 4,834 $ (headline result)
  • Tooling maintenance cost per unit: 201 $ / piece
  • Variable tooling maintenance cost: 4,234 $
  • Fixed tooling maintenance cost adder: 600 $

Run it with your numbers

  • Every input above is editable in the live Tooling Maintenance Cost calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.