Acervas · Downtime ROI
A point off your downtime, in minutes per shift.
Use your own numbers. See what a modest, believable reduction in unplanned downtime is actually worth — and how little has to change on each shift to get there.
What you're actually asking the line to do
Take unplanned downtime from 8% to 6.8% — about a 15% cut in lost time.
On the floor, that's recovering
Recovering 5 minutes 46 seconds per 8-hour shift — worth $262,080 a year.
Method: running hours × current downtime % × your hourly cost = today's annual loss. The reduction is applied as percentage points off the downtime rate, then the recovered hours are spread across a year of shifts. Conservative inputs are the point — the number should look achievable, because it is.
The hard part isn't the maths — it's the minutes.
You don't find those minutes by working harder on your own line. You find them because another plant running the same equipment already solved the fault you're about to hit. That shared fault history — across tenants, kept private to each — is what Acervas turns into recovered shifts.
Downtime ROI — frequently asked
- How much does an hour of unplanned downtime cost?
- It varies enormously by line, which is why the calculator uses your own number. On continuous, cascading production — where one machine going down stops the whole line — an hour of unplanned stoppage commonly runs into the tens of thousands once lost throughput, not just labour, is counted. Enter your true figure and everything else follows from it.
- What counts as unplanned downtime?
- Any unscheduled stop as a share of running time — breakdowns, faults, jams, and the time spent diagnosing them. Planned maintenance windows and scheduled changeovers are not unplanned downtime, so leave them out of the percentage you enter.
- Is a one-point reduction in unplanned downtime realistic?
- Yes — that is the point of the default. The calculator uses a small, believable figure (for example 8% down to 6.8%) rather than a best case. A single percentage point off the rate is the kind of improvement a team can actually hold shift after shift, which is why the resulting number should look achievable.
- How is the annual saving calculated?
- Running hours × current downtime % × your hourly cost gives today’s annual loss. The reduction is applied as percentage points off the downtime rate; the recovered hours are then valued at your hourly cost and spread across a year of shifts, which is what produces the minutes-per-shift figure.
- How does Acervas actually reduce downtime?
- By putting the fix in front of your team before they need it. When another plant running similar equipment has already solved the fault you are about to hit, that shared fault history — kept private to each organisation — becomes minutes recovered on your line. The hard part is never the maths; it is finding those minutes, and you find them across the network rather than alone.