Annualised downtime cost
Failures per month × repair hours × 12 × cost per downtime hour
Free reliability tool
What is downtime really costing you?
Turn a few maintenance assumptions into an estimated annualised downtime cost—then see the MTBF, MTTR, and availability measures behind it.
NO SIGNUPNO AI CALLNO DATA STORED
CALCULATOR INPUTS
Start with a useful estimate.
ESTIMATED ANNUALISED DOWNTIME COST
$240,000Based on 96 hours of downtime each year.Monthly downtime8 hrs
MTBF estimate256 hrs
MTTR estimate4 hrs
Schedule-based availability98.46%
No signup required. This is a planning estimate, not an accounting result. Replace the examples with your own operating and cost data before making a decision.
Run a PM gap analysisRead the number properly
A useful estimate is
transparent about its limits.
Downtime cost is rarely just the invoice for a repair. Depending on your operation, it can include missed production, labour, energy, quality losses, expedited parts, and the knock-on cost of a delayed schedule. Enter the hourly impact that makes sense for the scope you are measuring: one asset, a line, or an entire site.
MTBF and MTTR
Scheduled hours per month ÷ failures, alongside the repair time you entered.
Schedule-based availability
1 − monthly unplanned downtime ÷ monthly scheduled operating hours
Assumptions & boundaries
Use the result to ask a better question.
The estimate annualises your current pattern. It does not forecast when a failure will occur, prove causation, or guarantee savings.
Scope matters. Keep the asset, line, or site boundary consistent when comparing costs. Do not mix a single machine’s repair time with a site-wide hourly production value.
Engineering review still matters. Validate the data, failure definition, planned-downtime treatment, and cost model before changing a maintenance strategy.
Common questions
Before you
use the number.
What is downtime cost?
Downtime cost is the estimated financial impact of an asset or process being unavailable. It can include lost production, labour, energy, quality losses, missed output, and other local consequences. This calculator uses the hourly cost you provide rather than assuming an industry average.
How is annualised downtime cost calculated?
The estimate is failures per month multiplied by average repair hours, multiplied by 12 months, multiplied by downtime cost per hour. It annualises the monthly pattern you enter; it does not predict the timing of future failures.
What is the difference between MTBF and MTTR?
MTBF, or mean time between failures, estimates the scheduled operating hours between unplanned failures. MTTR, or mean time to repair, is the average downtime required to restore the asset. Both are historical or planning measures and depend on the quality and scope of the data.
Is this availability calculation the same as OEE availability?
No. This tool shows a schedule-based availability estimate using the scheduled hours and unplanned downtime you enter. OEE availability and other reliability measures may use different boundaries, exclusions, and data rules.
Can I use this for a whole plant or production line?
Yes, but state the scope clearly. The result describes whichever asset, line, or site your four inputs represent. Combining several assets can hide the individual failure patterns, so use consistent boundaries when comparing results.
From estimate to evidence
Find out what your
current PM plan misses.
Create a free NexPhase workspace to compare maintenance sources, work history, and PM coverage with an engineer-reviewable gap analysis.