Why does a longer response lower the cost per minute?

The event cost is set by the units lost and the resources that stood waiting, then spread over the minutes. More minutes lowers the rate, so compare the delay against target instead.

A signal that a production problem needs a response, raised by a worker, a cord, a button or the equipment itself. It exists so help arrives before a small stop becomes a large loss.

Should standing labor include supervision?

Include anyone who stopped productive work to watch the response, supervision included. Leave out people who kept working somewhere else on the line.

How do I set the target response time?

Use the response your escalation policy promises, or the delay where lost units start climbing sharply. The target you enter is the only warning threshold on this page.

Conveyors calculator

Andon Response Time Cost Calculator

Price the units an andon delay lost, the labor that stood waiting and the escalation it triggered. Enter the lost count, unit value, adders, response delay and target.

What this calculator does

What an andon response delay costs in lost unit value and standing resources, against the response target you set.

Formula used

Lost unit value = units lost during the andon delay × value per delayed or lost unit
Labor and escalation adders = standing labor during the delay + escalation, scrap or expedite adders
Andon response delay cost = lost unit value + labor and escalation adders
Cost per lost unit = event cost ÷ units lost in that event; cost per response minute = event cost ÷ that event's delay minutes
Response gap = response delay minutes − target response minutes

Inputs explained

Units Lost During Andon Delay: Good units lost while the response delay ran.
Value per Delayed or Lost Unit: Contribution value each delayed or lost unit carries.
Standing Labor During Response Delay: Crew cost while the line stood waiting for help.
Escalation, Scrap, or Expedite Adders: Escalation, scrap and expedite charges this event caused.
Response Delay: Minutes from the andon signal to the fix starting.
Target Response Time: Response time the escalation policy promises this line.

How to use the result

Best suited to pricing a slow response to a jam, justifying an andon escalation policy, comparing response cost across shifts.
Units lost are entered from the stop record; the delay does not derive them. Adders are charges for this event, not per-minute rates to reuse.

Current U.S. benchmarks

The U.S. has 21,668 machinery manufacturing establishments employing about 1,086,146 workers (Census County Business Patterns, 2023).

Common questions

Why does a longer response lower the cost per minute? The event cost is set by the units lost and the resources that stood waiting, then spread over the minutes. More minutes lowers the rate, so compare the delay against target instead.
What is an andon? A signal that a production problem needs a response, raised by a worker, a cord, a button or the equipment itself. It exists so help arrives before a small stop becomes a large loss.
Should standing labor include supervision? Include anyone who stopped productive work to watch the response, supervision included. Leave out people who kept working somewhere else on the line.
How do I set the target response time? Use the response your escalation policy promises, or the delay where lost units start climbing sharply. The target you enter is the only warning threshold on this page.

Last reviewed 2026-10-01.