Free calculator

Equipment Downtime Cost Calculator

Unplanned downtime is usually the largest hidden cost in maintenance. Enter your own figures to estimate what breakdowns cost per year and what you could save by preventing a share of them with planned maintenance and a CMMS.

Downtime cost / year60,000
Repair cost / year38,400
Total unplanned cost / year98,400
Potential savings / year29,520

Figures are in your own currency and are only as accurate as the numbers you enter.

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How to use the equipment downtime cost calculator

  1. Count unplanned downtime hours for your critical assets in a typical month (from shift logs or your CMMS).
  2. Estimate the cost of one hour of downtime: lost production margin, idle labour, overtime, scrap and penalties.
  3. Add the average repair cost per breakdown (parts, contractor and technician time).
  4. Choose the share of breakdowns you believe planned maintenance could prevent — start conservatively.

The formula

  • Yearly downtime cost = monthly unplanned downtime hours × cost per downtime hour × 12.
  • Yearly repair cost = breakdowns per month × average repair cost × 12.
  • Total cost of unplanned downtime = downtime cost + repair cost.
  • Potential savings = total cost × the share of breakdowns you expect preventive maintenance to avoid.

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FAQs

How do you calculate the cost of downtime?

Multiply downtime hours by the cost of one hour of downtime (lost margin, idle labour, overtime, scrap and penalties), then add repair costs. This calculator does it monthly and yearly with your own numbers.

What is included in the cost of one downtime hour?

Typically lost production margin, wages for idle operators, overtime to catch up, scrapped material, expedited parts and any contractual penalties.

How does a CMMS reduce downtime?

A CMMS schedules preventive maintenance by time or run hours, records failure history so repeat problems are fixed at the root, and keeps critical spares in stock — reducing both the number and length of breakdowns.

Can I reference this calculator?

Yes — link to this page. The full formula is published on the page.

Cite this calculator

Writing about call handling or maintenance costs? Link readers to this free tool:

<a href="https://www.zetsapp.com/tools/equipment-downtime-cost-calculator">Equipment Downtime Cost Calculator by ZetsApp</a>