OEE & Factory Performance worked example

Downtime Cost Calculator at 92% capacity-recovery share: a worked example

What does the result look like when capacity-recovery share reaches 92%? The full calculation is worked below with real intermediate numbers. Use it when downtime cost in oee and factory performance is being put through a oee and factory performance weighted-cost review.

The inputs for this scenario

  • Downtime hours: 100 hr (unchanged)
  • Cost per downtime hour: 45 $ / hr (unchanged)
  • Capacity-recovery share: 92 % (raised for this scenario; the documented default is 80)
  • Fixed response cost: 250 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Weighted cost = quantity × rate × capture factor + fixed adjustment) to the inputs above produces each figure below.
  • At this operating point the engine returns 4,390 $ for total downtime cost, the number this scenario is built around.
  • At this operating point the engine returns 43.9 $ / piece for downtime cost per unit.
  • At this operating point the engine returns 4,140 $ for variable downtime cost.
  • At this operating point the engine returns 250 $ for fixed downtime cost adder.

How this compares with the baseline

  • Against the tool's baseline example, where capacity-recovery share sits at 80% and the headline result is 3,850 $, this scenario comes in 14.03% above the baseline at 4,390 $.
  • A figure at this level is achievable when capacity-recovery share is genuinely sustained, not just peaked for a shift. It is a weighted estimate, not full activity-based costing; the result is only as good as your rate and capture-factor assumptions, which can vary widely by whether the lost output was truly sold-out demand.

Results at a glance

  • Total downtime cost: 4,390 $ (headline result)
  • Downtime cost per unit: 43.9 $ / piece
  • Variable downtime cost: 4,140 $
  • Fixed downtime cost adder: 250 $

Run it with your numbers

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

Last reviewed 2026-05-12.