Downtime Cost Calculator

Enter cost parameters to quickly estimate direct losses per minute / hour of downtime.

Basic Settings

Total Hourly Labor Cost

Sum of wages for all operators and technicians on shift

NT$/ hr

Overhead Rate

Admin, utilities, depreciation etc. as % of labor cost

% of labor

Capacity & Material Loss

Normal Hourly Production Value

Value of products produced per hour during normal operation

NT$/ hr

Material Loss Rate

Material waste / rework during downtime as % of normal production value

% of output

Hourly Cost Breakdown

Labor CostNT$ 2,500 (71%)

OverheadNT$ 750 (21%)

Material LossNT$ 250 (7%)

Loss per Minute

NT$ 58

Direct cost per 1 min downtime

Loss per Hour

NT$ 3,500

Direct cost per 1 hr downtime

Per Shift (8 hr)

NT$ 28,000

Full shift downtime estimate

Per Day (24 hr)

NT$ 84,000

Full day downtime estimate

Custom Downtime Duration Estimate

30 min downtime loss

NT$ 1,750

Report Preview

Downtime Loss Report
========================================
Date: 07/19/2026
Basis (per hour):
  - Labor cost: NT$ 2,500
  - Overhead: NT$ 750 (30% of labor cost)
  - Material loss: NT$ 250 (0.5% of output value)

Downtime loss estimate:
  Per minute: NT$ 58
  Per hour: NT$ 3,500
  Per shift (8h): NT$ 28,000
  Per day (24h): NT$ 84,000

Note: This report covers directly quantifiable
      costs only; indirect losses such as capacity
      displacement and contract penalties are excluded.
========================================

Note: This tool estimates only directly quantifiable costs (labor, overhead, material loss). Indirect costs such as order penalties, customer trust loss, and opportunity costs are excluded. Actual downtime losses are typically higher.

Use Case

Equipment supervisors must report downtime losses to management every month. The downtime cost calculator combines direct costs (lost capacity + repair fees) and indirect costs (idle labor + order delays) to quantify the true financial impact of each downtime event, providing an ROI basis for preventive maintenance investment decisions.

Example

An injection molding machine is down for 2 hours. Hourly capacity = 150 pcs, defect rate 2%, unit price NT$800, gross margin 35%. Direct capacity loss = 2 × 150 × 0.98 × 800 × 35% = NT$82,320. Add repair cost NT$12,000 and idle operator cost NT$3,500. Total downtime cost = NT$97,820 (≈ NT$48,910 per hour). If a NT$150,000/yr preventive maintenance program avoids 4 similar events, ROI = (4 × 97,820 - 150,000) / 150,000 = 160%.

Further reading: Downtime cost analysis & preventive maintenance ROI

View articles →

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