Free tool
Downtime cost calculator
Put a ₹ figure on unplanned downtime. Four inputs, honest defaults — adjust them to your plant.
Use your fully loaded machine-hour rate — operator, power, overheads, and the margin on parts the machine should have made. Most plants recover a meaningful share of this within months of naming their top three downtime causes.
Why the number is bigger than it feels
Downtime is experienced in 5-minute pieces, so nobody feels the annual total. Forty-five minutes a day per machine feels normal — across fifteen machines it is nearly 300 lost machine-hours a month.
The machine-hour rate matters as much as the minutes. A rate that only counts the operator’s wage understates the loss; the honest rate includes power, overhead absorption, and the contribution margin of the parts that were never made.
The first step to recovering any of it is knowing where the minutes actually go — measured from the machines, with causes named by the people standing next to them. That is precisely what ThingConnect does.