Free tool
What is unplanned downtime and energy waste costing you?
Enter a few numbers from your plant to estimate the yearly value of machine condition monitoring and power monitoring. All calculations run in your browser.
Estimated yearly value
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- Avoided downtime
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- Lower repair costs
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- Energy savings
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- Over 3 years
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Indicative only, based on your inputs. Actual results vary by site, asset mix and how quickly findings are acted on.
How to get the most accurate estimate
Pull unplanned downtime hours from your CMMS or shift logs for the last 12 months and include only the assets you'd monitor. For cost per hour, ask finance for the contribution margin per hour of output on the affected line, then add labour and scrap. Use reactive repair spend from purchase orders tagged as breakdown or emergency.
Want help building the business case? Book a demo and we'll work through it with your numbers.
Frequently asked questions
How is the downtime saving calculated?
Annual unplanned downtime hours × cost per hour of downtime × the share of that downtime you expect early warning to prevent. The default reduction is deliberately conservative. Adjust it to match your own experience.
What should I include in the cost of one hour of downtime?
Lost contribution margin on the production you couldn't make, overtime to recover, scrap and rework, expedited freight and any contractual penalties. Many plants underestimate this figure because it isn't in one budget line.
Is a 5% energy saving realistic?
For many plants that have never sub-metered, yes. Typical early wins are idle loads, compressed air leaks and peak demand. Your actual result depends on your tariff, equipment and how quickly you act on the data.