DIFM OS / ROI Model / Downtime Economics

Find out what unplanned downtime is actually costing your plant.

Enter your shift rates and line stoppages. See your true monthly loss in 60 seconds, and the net return of preventing it.

Your operation

Conservative baseline: excludes scrap, OEE drift and warranty costs, so your real figure is likely higher.

Currency

Labour

Engineer hourly rateEngineers affectedOperator hourly rateOperators affected

Downtime profile

Avg downtime per incident (min)Incidents per monthProfit per machine / hourMachines with similar issuesPenalty / late delivery per incident

Solution comparison

Compare to a solution cost?

Monthly solution cost

Benchmark baseline for a 300-asset plant with unlimited floor users. Your actual investment is fixed and capped, based on the exact operational modules your lines need. No surprise seat fees.

Impact visualisation

Before vs After DIFM

Before DIFM · Loss accumulation

What unplanned downtime costs you if nothing changes.

£4,208/mo burn

Cumulative downtime loss

Each incident costs £526. With 4 incidents a month across 2 machines, losses compound to £50,496 in 12 months through idle labour, lost machine profit and penalties.

Per incident: £526
Per month: £4,208
12-month total: £50,496

After DIFM · Cost curve flattened

Your spend is capped: a flat, predictable plant investment.

76% loss avoided

Before · unmitigated lossWith DIFM · total spend

At £1,000/month, your 12-month spend is £12,000 instead of £50,496. The gap between the two lines is money you keep: £38,496 a year. This pays for itself in 7 days.

Annual spend: £12,000
Annual avoided: £38,496
Payback: 7 days

Net Savings with Solution

Monthly

£3,208

Annual

£38,496

An investment of £1,000/mo (£12,000 annually) prevents a projected loss of £50,496, delivering a direct 4.2× monthly return.

Your Results

Downtime Cost per Hour

Engineers Cost (2 × £18/hr):£36

Idle Operators Cost (8 × £15/hr):£120

Lost Machine Profit (per machine / hour):£3,000

Total Hourly Operating Loss:£3,156

Cost Breakdown per Incident

One incident lasts 10 min (0.17 hr), so each hourly figure below is charged for 0.17 of an hour.

Engineers Labour (10 min):£6

Idle Operators (10 min):£20

Lost Production Profit (10 min):£500

Operating Loss during Incident:£526

Penalty Cost (per incident):£0

Total Loss per Incident:Loss£526

Labour, idle operators and lost production for one machine, plus penalties. Monthly impact then multiplies this by 4 incidents × 2 machines.

Total Downtime Impact

Net Monthly Savings:Saving£3,208

Net Annual Savings:Saving£38,496

Every week this stays unfixed costs about £971 in unrecovered downtime.

Next Steps

Your downtime is costly. Take action to mitigate these losses and protect your throughput.

Instant download. No call needed. Forward it to your Plant Director or Finance.

Reclaim this loss with DIFM

20 minute call with an engineer. No sales pitch. Keep your plant plan free.

Indicative model. Outputs depend on inputs and exclude secondary impacts such as scrap, OEE drift, and warranty exposure. These estimates are for illustration only. They are not financial, engineering or safety advice and should not be the sole basis for a purchasing or budgeting decision. See our Terms.