Downtime Cost Calculator (AUD)

Inputs

Total downtime per week (hours)

Example: 5 hours/week across breakdowns, changeovers, waiting on parts, etc.

People affected (count)

How many people are paid but not producing value during downtime (operators, techs, supervisors)?

Fully-loaded labour rate (AUD/hour)

Use a fully-loaded rate if you can (wage + oncosts). If unsure, start with $55/hr.

Lost contribution (AUD/hour) (optional)

If your bottleneck stops, you often lose more than labour. Enter an estimate of lost margin/contribution per hour.

Working weeks per year

Use 48 for typical AU operations (allowing for shutdowns/holidays). Adjust as needed.

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Results

Labour cost per hour

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Total cost per hour (labour + contribution)

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Estimated annual downtime cost

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Cost per week

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Cost per month (avg)

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Enter your numbers to see the impact.

What to do next

If downtime is costing you real money, the next step is usually to capture reasons consistently and make the numbers visible.

Maintenance / CMMS — track downtime reasons, PM, spares and work orders.
Dashboards & reporting — stop spreadsheet firefighting and get trusted KPIs.
Talk to Nick — fixed-scope Phase 1 to reduce downtime and build the underlying system.

Disclaimer: This is an estimate for decision support. Real cost depends on your constraint, WIP, customer penalties, overtime, scrap, and recovery time.