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

Unplanned downtime, hours per month

Typical mid-size discrete plant: 15–40 h/month

Revenue per production hour (€)

Line revenue ÷ scheduled hours; automotive lines run far higher

Contribution margin on lost output (%) · 40

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.