Conveyors worked example

Andon Response Time Cost with units lost during andon delay of 48 units: a worked example

This worked example runs the andon response time cost numbers for a tougher week than the baseline: units lost during andon delay of 48 units instead of the typical 95 units. Estimate the cost of delayed andon response from lost units, unit value, labor, and escalation adders.

The inputs for this scenario

  • Units lost during andon delay: 48 units (the input this scenario stresses; the baseline uses 95)
  • Value per delayed or lost unit: 6.4 $ / unit (held at the documented default)
  • Standing labor during response delay: 210 $ (held at the documented default)
  • Escalation, scrap, or expedite adders: 125 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Andon delay cost = lost units × value per unit + standing labor + escalation adders.
  • Andon response delay cost works out to 642 $ / event at these inputs, and this is the headline figure for the scenario.
  • Cost per lost unit works out to 13.38 $ / unit at these inputs.
  • Lost unit value works out to 307 $ at these inputs.
  • Labor and escalation adders works out to 335 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where units lost during andon delay sits at 95 units and the headline result is 943 $ / event, this scenario comes in 31.9% below the baseline at 642 $ / event.
  • Use it when setting andon response-time targets or building the business case for additional responders or a faster escalation chain. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Andon response delay cost: 642 $ / event (headline result)
  • Cost per lost unit: 13.38 $ / unit
  • Lost unit value: 307 $
  • Labor and escalation adders: 335 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Andon Response Time Cost calculator, set units lost during andon delay to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.