Conveyors calculator
Andon Response Time Cost Calculator
Use this calculator when a line stop, quality call, or material shortage waits for support. It translates response delay into cost so supervisors can justify faster escalation, better coverage, or clearer andon rules.
What this calculator does
- Estimate the cost of delayed andon response from lost units, unit value, labor, and escalation adders.
- a production manager needs to quantify the cost of slow response to line-down andon calls
- The result estimates the cost of one delayed andon response event.
Formula used
- Andon delay cost = lost units × value per unit + standing labor + escalation adders
- Cost per lost unit = delay cost ÷ units lost
Inputs explained
- Units lost during andon delay: Use delay minutes multiplied by the line's expected output rate.
- Value per delayed or lost unit: Use contribution, conversion value, or customer-impact value.
- Standing labor during response delay: Include operators, team leads, quality, maintenance, or material handlers waiting on response.
- Escalation, scrap, or expedite adders: Add scrap, premium freight, overtime, or customer-impact cost tied to the delay.
How to use the result
- Use it for team-leader staffing, escalation standards, maintenance response targets, and improvement reviews.
- It does not measure root cause; it only monetizes the delay after the call is raised.
Common questions
- What is Andon Response Time Cost for? Estimate the cost of delayed andon response from lost units, unit value, labor, and escalation adders.
- What information do I need before using it? You need lost units during response delay, value per unit, standing labor, and any escalation or scrap adders.
- When is the result only an estimate? The result is an estimate when lost units or labor cost is based on standard rates instead of event-specific data.
- How can I use the result on the line? Use the cost to set response-time targets, justify support coverage, or prioritize recurring andon categories.
Last reviewed 2026-05-12.