How to use
Enter hourly production loss, the average length of an unplanned failure and its repair cost.
Enter the cost and duration of fixing the same problem in a planned stop (e.g. balancing, alignment, bearing replacement).
Both scenarios are totalled for the number of failures per year.
Theory & formulas
Unplanned failure cost = hourly loss × downtime + repair cost. Annual cost multiplies this by failures per year.
Planned intervention cost = intervention fee + hourly loss × planned downtime. Planned stops usually fall between shifts or on maintenance days, so time and loss are lower.
Adding secondary damage (shaft, housing, winding), emergency parts and overtime usually makes unplanned failures costlier still.
Frequently asked questions
Which numbers should I use?
For hourly loss use the lost contribution margin or production value while stopped; for repair, the average parts and labour of recent failures. If unsure, run it twice with low and high estimates.