OEE & Factory Performance worked example

Downtime Cost Calculator at 58% capacity-recovery share: a worked example

Suppose capacity-recovery share falls to 58%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Estimate downtime cost from lost hours, hourly margin, capture factor, and restart cost.

The inputs for this scenario

  • Downtime hours: 100 hr (held at the documented default)
  • Cost per downtime hour: 45 $ / hr (held at the documented default)
  • Capacity-recovery share: 58 % (the input this scenario stresses; the baseline uses 80)
  • Fixed response cost: 250 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Weighted cost = quantity × rate × capture factor + fixed adjustment.
  • Total downtime cost works out to 2,860 $ at these inputs, and this is the headline figure for the scenario.
  • Downtime cost per unit works out to 28.6 $ / piece at these inputs.
  • Variable downtime cost works out to 2,610 $ at these inputs.
  • Fixed downtime cost adder works out to 250 $ at these inputs.

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 25.71% below the baseline at 2,860 $.
  • It computes total downtime cost as quantity times rate times a capture factor, plus a fixed dollar adjustment, and breaks out the per-unit and variable components. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.

Results at a glance

  • Total downtime cost: 2,860 $ (headline result)
  • Downtime cost per unit: 28.6 $ / piece
  • Variable downtime cost: 2,610 $
  • Fixed downtime cost adder: 250 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Downtime Cost Calculator calculator, set capacity-recovery share to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.