Cost of Unplanned Downtime
Downtime Cost Calculator
Most plants know their downtime in hours. Few know it in rupees. Enter one line's monthly downtime and its cost drivers, and see the annual figure — split into margin that was never earned and overhead that kept running anyway.
Calculator
Tell us about the line:
Breakdowns and unplanned stops on this line, in hours.
Selling price minus material and other variable cost.
Labour plus fixed costs — power, rent, supervision — still running while the line is stopped, per hour.
Well-run plants hold unplanned downtime under 5% of planned time — about 20 hours a month on a two-shift line.
Unplanned downtime is costing you every year
₹1.33 Cr
Where the money goes:
Lost units per month
15,960 units
Hours lost per year
456 hrs
Margin never earned
₹1.24 Cr
Idle overhead
₹8.21 L
Want to know more?
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One number usually points at another.
OEE Calculator
Availability, performance and quality for one line, one shift — and the capacity hiding inside the gap to 85%.
Changeover Savings Calculator
Production hours lost to changeovers each year, and the value a setup-reduction programme would release.
Labour Productivity Calculator
Units per labour-hour against your own target rate, and what the gap between them costs every year.
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