📉 Manufacturing
Downtime Calculator
Calculate machine downtime %, production units lost and revenue impact. Also calculate MTBF, MTTR and machine availability in one tool.
e.g. 8 hrs for one shift
Sum of all stoppages
📊 Downtime Analysis
Downtime %
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Availability %
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Uptime / Shift
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Monthly Downtime
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How to Calculate Downtime
Downtime % = (Total Downtime ÷ Planned Time) × 100
Availability % = 100% − Downtime %
Production Loss = Downtime (min) × 60 ÷ Cycle Time (sec)
Revenue Lost = Units Lost × Revenue per Unit
Downtime Benchmarks
| Availability | Rating |
|---|---|
| Above 95% | World class |
| 90–95% | Good |
| 80–90% | Average — review PM |
| Below 80% | Poor — urgent action |
🔗 Related Calculators
Downtime Calculation Formula — Explained
Downtime % = total time the machine was stopped (planned + unplanned) divided by total planned production time. In OEE, only unplanned downtime and changeovers beyond standard time count — scheduled breaks are excluded from planned time.
Types of Downtime in Manufacturing
| Type | Examples | OEE Impact |
|---|---|---|
| Planned | Scheduled maintenance, breaks | Excluded from OEE |
| Unplanned | Breakdown, tool failure | Availability loss |
| Changeover | Die change, product change | Availability loss |
| Minor stops | Jam, sensor trip (<5 min) | Performance loss |
How to Reduce Downtime
- Implement Preventive Maintenance (PM) schedules — fix before it breaks
- Track every breakdown with root cause — eliminate repeat failures
- Keep critical spare parts in stock to reduce MTTR
- Train operators on basic maintenance (TPM — Total Productive Maintenance)
- Monitor machine condition (vibration, temperature) for early warning
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