Why this matters
Downtime cost can include lost contribution, idle labor, delayed orders, overtime, quality losses, restart losses and downstream disruption. The correct model depends on whether the stopped machine is a true production constraint.
A practical decision framework
Start with verified project data: the product, process flow, required quality, target good output, operating hours and site conditions. Separate confirmed facts from assumptions, and use the same basis when comparing alternatives.
Key inputs
Estimate the economic impact of lost good output and any idle labor, overtime, delay, quality or restart losses. Avoid double counting and identify whether the asset is the bottleneck.
What to include in the calculation or review
Use current supplier data and actual factory assumptions. Include the items that materially affect the decision, document exclusions, and test conservative, base and growth scenarios instead of relying on one optimistic number.
Common mistakes
Common errors include using theoretical capacity instead of saleable output, ignoring setup and ramp-up, omitting utilities or lifecycle costs, mixing assumptions with verified facts, and comparing alternatives on different scopes.
Before making the decision
Review the model with production, technical and finance stakeholders. Update variable prices, tariffs, financing terms and supplier quotations at the date of decision. For machinery, confirm the actual model manual, supply scope and acceptance criteria.
Frequently asked questions
Should one number be used as the final answer? No. Industrial decisions are stronger when the main assumptions are tested as ranges and scenarios.
Can SAKKARY MACHINERY help? SAKKARY MACHINERY can support the technical side of process definition, machinery selection, capacity planning, installation, training and lifecycle support based on verified project requirements.
Need a machine, tooling or a service visit?
Request a price
