Conveyors calculator
Microstop Loss Calculator
Use this calculator when frequent short stops do not look serious individually but drain line output over a shift. It helps teams convert microstops into units and dollars for loss elimination work.
What this calculator does
- Estimate the cost of repeated short conveyor or machine stops from lost units, value, labor, and scrap adders.
- a continuous improvement team needs to quantify the impact of short stops, jams, and resets
- The result estimates the financial impact of recurring short stops over the chosen period.
Formula used
- Microstop loss cost = lost units × value per unit + labor cost + restart adders
- Cost per lost unit = microstop loss cost ÷ lost units
Inputs explained
- Units lost to microstops: Estimate from total microstop minutes times standard line rate.
- Value per lost microstop unit: Use contribution, conversion value, or avoided overtime value.
- Labor cost during microstops: Include standing operators and support labor during the microstop window.
- Restart scrap or adjustment adders: Add scrap, giveaway, reinspection, or adjustment cost caused by restarts.
How to use the result
- Use it for jam studies, sensor issues, restart losses, packaging faults, and daily loss-tree reviews.
- It depends on reliable stop counting; many PLCs undercount very short stops unless configured correctly.
Common questions
- What is Microstop Loss for? Estimate the cost of repeated short conveyor or machine stops from lost units, value, labor, and scrap adders.
- What information do I need before using it? You need units lost to microstops, value per lost unit, labor cost, and restart scrap or adders.
- When is the result only an estimate? The result is approximate when microstop duration, frequency, or lost-unit conversion is estimated manually.
- How can I use the result on the line? Use the cost to justify fixing guides, sensors, transfers, change parts, or controls that cause repeated short stops.
Last reviewed 2026-05-12.