Downtime Cost Calculator
Every stop on the floor costs money — people standing, machines idle, orders slipping. Most plants never put a number on it, so it never gets fixed. Plug in your own numbers below. Nothing you enter is saved or sent anywhere.
Wages plus benefits and overhead. If unsure, use your average hourly rate.
Based on 52 weeks, minus about 10 holidays. Adjust for your plant.
What an hour of production is worth to you. Leave blank to count labor only.
Your downtime cost
Fill in the first five fields to see your numbers.
Labor = people × hourly cost × (minutes ÷ 60) × shifts × days.
Get the one-page overview
The full picture in one page — features, pricing, and what setup looks like.
Where does it go?
A number this size usually isn't one big breakdown. It's a dozen small stops — waiting on material, a changeover that ran long, a forklift nobody could find. The only way to shrink it is to see which ones cost the most.
Andon Tool logs a stop in a few taps and ranks your causes by time lost.
FAQ
- What counts as downtime?
- Both kinds: unplanned stops like breakdowns and waiting on material, and planned ones like changeovers and meetings. Track both; the planned kind is often where the easy wins are.
- Why use loaded labor cost?
- Because a stop costs you more than wages. Benefits and overhead keep running while people wait.
- Is anything I enter saved?
- No. The calculator runs in your browser. Nothing is stored or sent.