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Most manufacturers underestimate the true cost of unplanned downtime by 50% to 200%<\/strong>. The “obvious” cost is direct: maintenance labor, spare parts, lost production hours. But the real cost includes scrap from restarts, idle energy consumption, expedited shipping for missed deliveries, overtime labor, and \u2014 biggest of all \u2014 lost margin on undelivered production.<\/p>\n This calculator gives you a category-by-category breakdown of your true annual downtime cost<\/strong>, calibrated on data from 450+ TeepTrak deployments across 30 countries between 2018 and Q2 2026. Typical mid-market plants discover their real downtime cost is $300K to $800K per year for a 5-line factory \u2014 most of it invisible until measured.<\/p>\n Adjust the sliders below and the numbers update live. No signup required.<\/strong> See how much you could recover with 25%, 50%, or 75% downtime reduction.<\/p>\n