Operational diagnostic
Production Instability Cost Calculator
Unplanned stops. Material shortages. Quality holds. Missed deliveries. Different symptoms. Same result: productive value is lost. Estimate what instability may be costing your operation each year.
Calculator
Tell us about your operation:
Count the lines or major production assets affected by disruption.
Fully loaded cost per operator hour — wages plus statutory and benefit costs — averaged across skill levels.
= ₹12 crore a year
Ex-works value of goods produced per month. 1 lakh = ₹1,00,000.
5 sits at roughly weekly disruption.
Year-one capture rates stay within the 35–50% band our engagements plan against.
Estimated Annual Value Opportunity
₹90,06,707
≈ ₹0.90 crore a year
Where the estimated cost is coming from:
Lost production time
Unplanned stops, changeovers and waiting.
₹54,00,000
Quality loss & rework
Reprocessing, scrap and lost first-pass output.
₹10,56,707
Delivery disruption
Expediting, delayed fulfilment and penalties.
₹25,50,000
Want the detailed breakdown?
Get the assumptions behind your estimate and see which loss areas are worth investigating first.
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%.
Downtime Cost Calculator
What an hour of a stopped line really costs, and what that adds up to across a year.
Changeover Savings Calculator
Production hours lost to changeovers each year, and the value a setup-reduction programme would release.
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