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What does unplanned downtime cost you?
Unplanned downtime is the most under-measured cost in most plants. Enter three numbers you already know; the calculator shows the annual bleed and what condition-based maintenance typically recovers.
Inputs
Typical mid-size discrete plant: 15-40 h/month
Line revenue ÷ scheduled hours; automotive lines run far higher
If capacity-constrained, lost output is lost margin
The math. Annual cost = hours/month × 12 × revenue/hour × margin%. Recovery scenarios apply the 20-50% range condition-based programs typically deliver.
Readout
Annual downtime cost·
Recovered at 20% (conservative)·
Recovered at 35% (typical)·
Recovered at 50% (best programs)·
Context: unplanned downtime costs the Fortune Global 500 an estimated ~11% of revenues (Siemens, The True Cost of Downtime). Condition-based maintenance programs typically recover 20-50% of unplanned stops.
Next stepTake the number to the Reducing unplanned downtime, in the order that pays playbook, or get the ROI workbook: all four calculators in one sheet, with scenario columns, for your budget meeting.
Free ROI workbook
Leave with the number, not a bookmark.
All four loss calculators (downtime, OEE, scrap, energy) in one Excel sheet, with conservative / typical / best-published scenario columns. Built for your budget meeting.
It's yours.
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The downtime number your finance director will accept
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