Reliability & Downtime

Downtime Cost per Hour Calculator

Downtime Cost per Hour Calculator takes units per hour, contribution margin per unit, idle crew size and rate, and your own scrap-and-restart and expedite costs per event and returns a downtime $/hr per production line, a cost per stoppage event, and what a one-hour or four-hour stop costs you. Downtime Rate ($/hr) = lost margin per hour (units per hour × margin per unit) + idle labour per hour (idle crew × their rate). Per-event costs — scrap and restart, expedite and recovery — are deliberately kept OUT of the $/hr figure because they do not scale with duration; they are added once per event. The cost of an N-hour stop is the rate × N plus one event cost. Nothing is pre-filled with an outside figure — no industry-average downtime cost, no cost-of-downtime benchmark, no reactive-versus-planned multiplier. Every value on every sheet is one you entered or one computed from what you entered, against the As-of date you set on 1. Setup, never today's date.