Free Maintenance Tools · Downtime Cost Calculator

What Does Unplanned Downtime Really Cost You?

Put in your line rate, what each unit is worth and how much the line is down. You get the yearly cost, split into lost margin and the labor standing around, with every formula shown so you can check it.

Unplanned downtime costs you about

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How It's Worked Out

downtime hours / year = downtime hours per week × operating weeks lost units / year = line rate (units per hour) × downtime hours / year lost margin / year = lost units / year × margin per unit labor / year = labor cost per hour × downtime hours / year cost per line / year = lost margin + labor total / year = cost per line × number of lines 10% less downtime saves = total × 10%

It leaves out scrap, overtime to catch up, expedited parts and late shipments, so the real number is usually higher. Your numbers aren't saved unless you ask us to email the result.

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