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Recover it with Fabrico
- Extra production output
- +9.4%
- Extra weeks of output a year
- 4.7 weeks
- Value a year
- €1,861,200
- New equipment
- None
Losses are found, priced and cut on the equipment you already have, with the full result in about 12 months.
Three numbers and two clicks are enough. The calculator prices your production losses the way Fabrico's financial impact module does, then shows how much of that cost MES and OEE software with CMMS built in can recover on your lines.
Cost of downtime calculator
Start with your bottleneck lines, the ones that set plant output. The sample is an FMCG plant at industry-average figures; change any number and the result updates.
Financial impact
If a loss has no price tag, it has no priority. These are the formulas Fabrico's financial impact module runs minute by minute on every line, applied to your numbers.
Profit lost a year against perfect production
What the first-year cuts recover, every year
+9.4% production output from the same lines
Weeks of output a year, from the same lines
Your top three: changeovers · small stops and slow cycles · breakdowns. Together they hold 74% of the recoverable value. Hansen’s rule: no more than three key projects at a time, bottlenecks first.
lost units × selling price€31,900/ hourwhen these lines stand stilllost units × gross margin€9,583/ hourwhen these lines stand stilllabor and overhead while the line waits€480/ hourwhen these lines stand stillSample data until you change the inputs. In Fabrico, the same formulas run in real time, with your selling price and gross margin per SKU, at shift, line, plant and group level.
The hidden factory
R.C. Hansen compares an OEE program with adding capacity: the program costs a fraction of the capital, takes months instead of years, and a new line may only run at the OEE you have today.
Losses are found, priced and cut on the equipment you already have, with the full result in about 12 months.
Capital project timings and the OEE caveat are from Hansen, chapter 3.
The principle
Recovered capacity is for meeting demand from the equipment you already have, not for building stock. That is why the calculator asks whether you can sell more.
Method
A first look a finance team can follow, built on the business-case method in R.C. Hansen's Overall Equipment Effectiveness. Every assumption is listed here.
OEE plus all losses equals 100% of scheduled time, split into six loss groups as in Hansen's worked example: breakdowns, changeovers, small stops and slow cycles, operator, procedure and material stops, scrap and rework, and waiting.
OEE = availability × performance × quality, before and after the first-year cuts. Production output rises in step with OEE.
If you can sell it: extra output × gross margin. If demand is flat: hours no longer needed × cost per hour. "Partly" splits it half and half. An hour stopped is priced as revenue at risk, profit and crew and energy.
Reactive work falls from 40% to 30% of maintenance, and a reactive repair costs three times a planned one (Hansen: 3 to 5 times). That saves about 11% of your maintenance budget.
R.C. Hansen, Overall Equipment Effectiveness: A Powerful Production/Maintenance Tool for Increased Profits (Industrial Press, 2001): loss classification, the "same output" and "sell everything" business cases, the OEE program vs capital comparison, reactive vs planned repair costs and the OEE ratings. S. Nakajima, Introduction to TPM: availability × performance × quality. Siemens, The True Cost of Downtime 2024: the FMCG cost of an hour of downtime, converted to euros (about €32,000).
See how it works in the product: real-time production monitoring and automatic downtime tracking in MES & OEE, maintenance management (CMMS), preventive maintenance and analytics and reporting.
It is a first look, built on R.C. Hansen’s OEE business-case method and your own numbers. In a pilot, Fabrico measures the real losses on one line, so the estimate is replaced by your own data within weeks. Review the result with your finance team before you decide.
Most plants that have not measured OEE run at about 60%. If you know the good output, the scheduled hours and the ideal rate of your bottleneck, OEE = good units ÷ (scheduled hours × ideal rate). The OEE calculator on fabrico.io walks you through it.
Because recovered capacity is only worth its margin if customers buy it. If demand is flat, the same gain comes back as fewer overtime and weekend hours. Hansen calls these the “sell everything” and “same output” cases; the real value usually sits between them.
No. Shorter breakdowns are counted once, as recovered output. The maintenance (CMMS) saving covers only repair costs: more of the work planned, less of it reactive.
Because Fabrico is quoted per plant, for the modules, lines and sites you choose. Use the opportunity as the size of the prize. In a 30-minute call we show what a quote for your plant includes, and a pilot line is live in days.
Nowhere, unless you choose to send them. The calculator runs in your browser. If you contact us from this page, you can attach your results so we can prepare for the call.
Next step
Bring one line and one week of stops. We'll price them with you and show what a pilot would prove.
Live demo
Pick a time that suits you. We show you Fabrico live and go through your calculator results.
A pilot site is operational in days, with minimal disruption to your teams.