Refractories, Furnace Linings & Foundry Consumables worked example

Furnace Downtime Cost at 92% share of lost output actually attributable: a worked example in refractories, furnace linings & foundry consumables

This scenario runs the furnace downtime cost calculation on the strong side: 92% share of lost output actually attributable, with every other input held at its documented default. Use it when furnace downtime cost in refractories, furnace linings and foundry consumables is being put through a refractories, furnace linings and foundry consumables weighted-cost review.

The inputs for this scenario

  • Furnace downtime hours: 100 hr (unchanged)
  • Lost-output cost per downtime hour: 45 $ / hr (unchanged)
  • Share of lost output actually attributable: 92 % (raised for this scenario; the documented default is 80)
  • Fixed reline or repair cost: 250 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Furnace Downtime Cost cost = quantity × rate × capture factor + fixed cost) to the inputs above produces each figure below.
  • At this operating point the engine returns 4,390 hr for weighted cost, the number this scenario is built around.
  • At this operating point the engine returns 43.9 $ / piece for per piece value.
  • At this operating point the engine returns 4,140 $ for captured value.
  • At this operating point the engine returns 250 $ for fixed adjustment.

How this compares with the baseline

  • Against the tool's baseline example, where share of lost output actually attributable sits at 80% and the headline result is 3,850 hr, this scenario comes in 14.03% above the baseline at 4,390 hr.
  • Use it after an outage to size the true loss, or before a planned reline to compare scheduled versus emergency scenarios. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Weighted cost: 4,390 hr (headline result)
  • Per piece value: 43.9 $ / piece
  • Captured value: 4,140 $
  • Fixed adjustment: 250 $

Run it with your numbers

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

Last reviewed 2026-05-12.