What is unplanned downtime really costing your plant?
Enter your numbers below. The cost updates instantly — no signup, no spreadsheet. Most plants are surprised by the yearly number.
Use your best real figures. Even a rough downtime estimate is enough to see the scale.
Count the machines or lines where unplanned stops hurt output.
Breakdowns, waiting, changeover overruns, no material, no operator — only unplanned time.
Lost sales value or burdened machine-hour rate — whichever your plant uses to value an hour.
50 is typical after holidays and planned shutdowns.
How this is figured: 5 machines × 4 hrs/week × 50 weeks = 1,000 hrs/year × $250/hr.
You don't fix downtime with a poster. You fix it by finding where the hours go, scoring the plant honestly, and working a plan week by week. That's exactly what the Plant Excellence Audit & Rollout Kit gives you — the same system, ready to run in your plant.
Comparable plant-assessment and TPM consulting engagements run $5,000 and up. This is the same system, in a kit you run yourself — and the software and templates match the compatibility of the big-name packages.
Try it with one problem line first. Put in that line's real downtime and rate — if the number still hurts on a single machine, you have your starting point for the audit.