What does unplanned downtime cost your line?

Enter your own numbers to estimate the weekly and yearly cost of lost production time. Nothing is sent anywhere; the calculation runs in your browser.

Unplanned downtime per shiftminShifts per weekshifts

Units produced per running hourunitsContribution margin per unit (price minus variable cost)CAD

Crew idle during a stoppeopleLoaded labour costCAD/h

Operating weeks per yearweeks

Estimated cost per week

–

Per year–

Lost running time per week–

Lost contribution margin per week–

Idle labour per week–

Value of cutting downtime by 10% per year–

Find out what's causing it

How the estimate works

Weekly cost = lost hours × (units per hour × margin per unit) + lost hours × crew × labour cost

Lost hours are your downtime minutes per shift multiplied by shifts per week, divided by 60. The estimate assumes that lost output isn't made up later without extra cost. If you recover it with overtime, the real cost shifts from lost margin to overtime pay, scrap and expediting.

What it leaves out

Scrap and rework when a line restarts
Overtime to catch up on missed orders
Late-delivery penalties and expedited freight
Slow running and minor stops, which often cost as much as recorded downtime

To see how downtime fits with speed and quality losses, read how to find your biggest production losses in 30 days.