How much is unplanned downtime costing your plant?
This free calculator estimates the annual cost of unplanned downtime from three inputs: downtime hours per month, the lost contribution margin per hour the line generates when running, and the emergency response cost per downtime hour. The lost margin is usually far larger than the repair, which is why downtime is so expensive.
Most plants record the repair cost of a failure but not its true cost. The true cost pairs lost production margin with emergency response. Enter your own figures below to size it. Everything stays in your browser; nothing is sent anywhere.
Total unplanned (failure-driven) downtime across the line or plant in a typical month.
Contribution margin (not revenue) the line generates per running hour. This is the profit you forgo per hour down.
Overtime labour, expedited parts, contractors, scrap and restart, averaged per downtime hour.
Uses contribution margin, not revenue, so it reflects profit actually lost. Assumes the monthly downtime figure is typical. Excludes harder-to-quantify costs such as customer and safety impact, so it is conservative.
Frequently asked questions
Should I enter revenue or margin per hour?
Is this calculator's figure exact?
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