A single unplanned stop rarely shows up as one line item anywhere. Repair labour goes through payroll. Parts go through a purchase order. Lost production doesn't get logged at all — it's just a quieter day that nobody adds up. This calculator adds all three together, per breakdown, then multiplies by how often it happens.
Annual cost = breakdowns/yr × cost per breakdown
Manufacturing finance and reliability sources consistently build this same way — lost production value plus repair labour plus parts, multiplied by how long the stop lasted. The structure isn't unique to Ryxen; the honesty of the inputs is what changes the answer.
A CNC machine that breaks down 8 times a year, averaging 5 hours of downtime each time, with a $70/hr repair rate, $400 in parts per incident, and $220/hr in lost production value while it's down.
- FREQUENCYBreakdown count from memory tends to be optimistic. A maintenance log or CMMS history will always beat a guess — use one if you have it.
- SCOPEThis treats every breakdown as average. If severity varies a lot — a jammed sensor versus a blown spindle bearing — an average can hide your worst cases.
- CASCADEA stopped machine can idle downstream work too — assembly, install crews waiting on parts. This only counts the machine you entered, unless you build that into your lost-value number.
- PARTSEmergency parts usually cost more than a planned order. Use what you'd actually pay in a pinch, not the catalog price.
- TRENDRun this again once you have a few months of real ServiceGrid history behind it. Today's number is a starting estimate, not a final answer.
Repair labour is visible — it's a payroll line or an invoice. Lost production is invisible — it's just fewer parts out the door, absorbed quietly into a slower week. Because two of the three costs here don't naturally show up anywhere, most shops underestimate reactive maintenance cost until they're forced to add it up explicitly, like this.
That's the whole point of building this as a calculator instead of a line in a spreadsheet nobody opens.