Downtime Cost Calculator
True cost of unplanned stops - weekly, monthly, annual.
Annual Downtime Cost
$450,000.00
Weekly
$9,000.00
Monthly
$37,500.00
Per Minute
$25.00
At this rate, downtime costs your operation $450,000.00 every year, planned and unplanned together. Unplanned stops alone account for $300,000.00, and halving those would save $150,000.00 annually.
Weekly Cost = Machines × Hourly Rate × (Unplanned + Planned Hours)
Hourly Machine Rate decides everything on this page, so choose it deliberately. When the line is your constraint and the hours are gone for good, use the contribution margin those hours would have earned, meaning price less material and variable cost. When you catch the volume back up, the honest rate is what catching up costs in overtime, expediting and extra setups, which is far below lost revenue. Unplanned Downtime and Planned Downtime are hours per machine per week, and Number of Machines multiplies them, so group only machines that stop together. Operating Weeks Per Year should leave out shutdown weeks.
Why is the cost per minute figure so high?
Because it covers the whole group. Cost per minute is Number of Machines times Hourly Machine Rate divided by 60, so ten machines at 150 dollars an hour reads 25 dollars a minute. That only holds if every machine stops at once. For one machine, set Number of Machines to one.
Does scheduled maintenance count as downtime cost?
On this page it does. Planned Downtime is added to Unplanned Downtime in the weekly, monthly and annual totals, because those hours still produce nothing. The savings bars work differently: both the 25 and 50 percent reductions are taken from unplanned cost alone, since the maintenance window is work you chose to do.
What is a normal amount of unplanned downtime?
This page publishes no benchmark, and a borrowed industry average would not survive contact with your process mix, asset age or changeover pattern. The comparison worth making is against yourself: hold Hourly Machine Rate and Operating Weeks Per Year fixed, and watch whether Unplanned Downtime hours per week fall month over month.
How is downtime cost different from lost revenue?
Lost revenue assumes a paying order sat behind every stopped hour and that no hour could be recovered. Downtime cost is what the stop actually took from you, which equals lost margin only when you are capacity constrained. With slack in the schedule, the real cost is the overtime, expediting and idle labour spent catching up.
What should I do with the annual downtime cost?
Measure the fix against it. The 25 and 50 percent savings bars give you the budget a spares programme, a condition monitoring sensor or a second trained operator has to beat. Then break your Unplanned Downtime hours down by machine and reason, because a handful of causes usually carries most of the hours.
Detect Downtime the Moment It Happens.
WorkCell alerts you to unplanned stops in real time and tracks every minute of lost production so you can take action before costs pile up.