Interactive tool
Production downtime cost calculator
The cost of a production stoppage is calculated by adding, for each hour stopped, the machine cost per hour, the cost of the affected operators and the margin of the units not produced. Enter your figures and the calculator returns the monthly and annual cost with its breakdown, with no sign-up and no data leaving your browser.
Downtime cost calculator
Machine cost
2,400 €
20 h × 120 €/h
Labour cost
1,500 €
20 h × 3 × 25 €/h
Margin not produced
0 €
No margin data
Monthly downtime cost
3,900 €
Machine + labour + margin
Annual downtime cost
46,800 €
Monthly cost × 12
Margin not produced is not being added: enter margin per unit and units lost per hour to include it.
How downtime cost is calculated
The monthly cost combines up to three components, all derived from your own data:
- Machine cost = downtime hours per month × machine cost per hour (€/h).
- Labour cost = downtime hours × operators affected × cost per operator hour (€/h).
- Margin not produced (optional) = downtime hours × units lost per hour × margin per unit (€/unit).
Annual cost = monthly cost × 12. The calculator applies no industry averages or hidden assumptions: the result is pure arithmetic over the values you enter, and the breakdown shows the formula applied to each component.
To reduce downtime hours, the first step is measuring them continuously: the plant monitoring guide explains how to capture stops and micro-stops, and the complete OEE guide shows how those stops impact your lines’ availability.
Frequently asked questions
- How is the cost of a production stoppage calculated?
- Three components are added for each downtime hour: the machine cost per hour (depreciation, energy, maintenance), the cost of the affected staff (operators × hourly cost) and, if known, the margin of the units that were not produced (units/hour × margin per unit). The monthly total is multiplied by 12 to obtain the annual impact.
- What data do I need to use the calculator?
- Four basic figures: unplanned downtime hours per month, machine cost per hour in euros, number of operators affected and cost per operator hour. Optionally, the margin per unit and the units lost per downtime hour, to include the margin not produced in the total.
- Does the calculator use industry benchmark data?
- No. The result is pure arithmetic over the data you enter: we do not apply industry averages or hidden assumptions. If you do not know a cost component (for example the margin per unit), you can leave it at zero and the breakdown will indicate it.
- Does the calculator store my production data?
- No. It runs entirely in your browser: the calculation is client-side arithmetic, with no network calls and no persistence. We do not send or store any data you enter.