1. Record the current baseline
Use your own maintenance records. Keep production rate, medium, duty cycle and failure criteria consistent between candidates.
- Part purchase price and delivery cost per replacement.
- Installation, removal and disposal cost per replacement.
- Unplanned downtime hours and the internally agreed cost per hour.
- Observed service hours and the reason the component was removed.
2. Calculate one comparable measure
Cost per operating hour = (part cost + replacement labour + attributed downtime cost) ÷ observed service hours. Use the same currency and scope for both alternatives.
- Keep planned maintenance downtime separate from unexpected failure.
- If the trial has not reached end of life, report the result as provisional.
- Count scrap or cleaning savings only when the trial measured them.
- Compare several service cycles where possible rather than selecting the best result.
3. Review the risks behind the average
A low average cost is not enough if a part fails unpredictably or disrupts the process.
- Track the range of achieved service life, not just the average.
- Record leakage, dimensional change, wear and process-quality observations.
- Include inspection effort, stocking needs and replacement lead time.
- Agree the acceptance decision with engineering, maintenance and purchasing.
4. Bring the baseline to your RFQ
Tell us what must improve. We can discuss the material and component requirements without promising an unverified life-extension percentage.
- Send the current drawing and material if known.
- Attach failure or wear photos and the operating conditions.
- State the minimum acceptable performance and test duration.
- Keep the approved test record with the final drawing revision.