Conveyors worked example

Microstop Loss with units lost to microstops of 130 units: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop units lost to microstops to 130 units, then walk the calculation through step by step. Estimate the cost of repeated short conveyor or machine stops from lost units, value, labor, and scrap adders.

The inputs for this scenario

  • Units lost to microstops: 130 units (the input this scenario stresses; the baseline uses 260)
  • Value per lost microstop unit: 4.25 $ / unit (held at the documented default)
  • Labor cost during microstops: 340 $ (held at the documented default)
  • Restart scrap or adjustment adders: 180 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Microstop loss cost = lost units × value per unit + labor cost + restart adders.
  • Microstop loss cost works out to 1,073 $ / period at these inputs, and this is the headline figure for the scenario.
  • Cost per microstop-lost unit works out to 8.25 $ / unit at these inputs.
  • Lost output value works out to 553 $ at these inputs.
  • Labor and restart adders works out to 520 $ at these inputs.

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 34% below the baseline at 1,073 $ / period.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to units lost to microstops, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. 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: 1,073 $ / period (headline result)
  • Cost per microstop-lost unit: 8.25 $ / unit
  • Lost output value: 553 $
  • Labor and restart adders: 520 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Microstop Loss calculator, set units lost to microstops to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.