Conveyors worked example

Microstop Loss with units lost to microstops of 650 units: a worked example

What does the result look like when units lost to microstops reaches 650 units? The full calculation is worked below with real intermediate numbers. a continuous improvement team needs to quantify the impact of short stops, jams, and resets

The inputs for this scenario

  • Units lost to microstops: 650 units (raised for this scenario; the documented default is 260)
  • Value per lost microstop unit: 4.25 $ / unit (unchanged)
  • Labor cost during microstops: 340 $ (unchanged)
  • Restart scrap or adjustment adders: 180 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Microstop loss cost = lost units × value per unit + labor cost + restart adders) to the inputs above produces each figure below.
  • At this operating point the engine returns 3,283 $ / period for microstop loss cost, the number this scenario is built around.
  • At this operating point the engine returns 5.05 $ / unit for cost per microstop-lost unit.
  • At this operating point the engine returns 2,763 $ for lost output value.
  • At this operating point the engine returns 520 $ for labor and restart adders.

How this compares with the baseline

  • Against the tool's baseline example, where units lost to microstops sits at 260 units and the headline result is 1,625 $ / period, this scenario comes in 102% above the baseline at 3,283 $ / period.
  • A figure at this level is achievable when units lost to microstops is genuinely sustained, not just peaked for a shift. Microstop unit counts are often estimated rather than logged; the result is only as accurate as your loss estimate, so validate with a short observation study.

Results at a glance

  • Microstop loss cost: 3,283 $ / period (headline result)
  • Cost per microstop-lost unit: 5.05 $ / unit
  • Lost output value: 2,763 $
  • Labor and restart adders: 520 $

Run it with your numbers

  • Every input above is editable in the live Microstop Loss calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.