Private, browser-only calculation. Blank means unknown; zero means none.
Your estimate
Replace calculator answers with an example? Contact details will stay unchanged.
Illustrative example, not a facility result.
Step 2Pull the production and payroll records
Not set
scheduled hours
08,760
The work orders carry the scheduled hours inside each stoppage.
Do those stoppages have a timestamped record naming a mechanical cause?
Yes means a trip log, an alarm, a work order or a service ticket carries the time.
Do those stoppages have a timestamped record naming a mechanical cause?. Blank means unknown; zero means none. The selected calculation identifies the financial role. Supporting facility and coverage answers are reported separately, not added to financial risk.
peopleNot set
05,000
The count is the operators and the material handlers who had nothing to run.
People who were on the clock and standing still while the line was down. Blank means unknown; zero means none. The selected calculation identifies the financial role. Supporting facility and coverage answers are reported separately, not added to financial risk.
The two figures at the ends of the slider are the smallest and the largest answers this box takes. They mark the edges of the question. Neither one is a typical figure for this plant, and neither one is a suggestion.
$Not set
dollars per hour per person
Market average: U.S. Bureau of Labor Statistics.
0500
The payroll register carries the wage and benefit cost of one clocked hour.
workersNot set
1100,000
The count is everyone on this plant's payroll.
People employed at this plant. Blank means unknown; zero means none. The selected calculation identifies the financial role. Supporting facility and coverage answers are reported separately, not added to financial risk.
The two figures at the ends of the slider are the smallest and the largest answers this box takes. They mark the edges of the question. Neither one is a typical figure for this plant, and neither one is a suggestion.
Does a breakdown or business interruption policy respond to this event?
Yes means the policy names this kind of failure and pays on a stopped line.
Does a breakdown or business interruption policy respond to this event?. Blank means unknown; zero means none. The selected calculation identifies the financial role. Supporting facility and coverage answers are reported separately, not added to financial risk.
percentNot set
A plant manager knows how much of that output never got made up.
What share of the lost output did the plant never make up?. Blank means unknown; zero means none. The selected calculation identifies the financial role. Supporting facility and coverage answers are reported separately, not added to financial risk.
Not set
good units per hour
01,000,000
The production record carries the good units that cell releases in an hour.
Good units that cell releases in one scheduled hour. Blank means unknown; zero means none. The selected calculation identifies the financial role. Supporting facility and coverage answers are reported separately, not added to financial risk.
The two figures at the ends of the slider are the smallest and the largest answers this box takes. They mark the edges of the question. Neither one is a typical figure for this plant, and neither one is a suggestion.
$per unitNot set
0100,000
Cost accounting carries the margin on one unit, not its price.
hoursNot set
0100,000
The payroll register carries the overtime hours paid after each stoppage.
Overtime hours the plant paid to make that production back. Blank means unknown; zero means none. The selected calculation identifies the financial role. Supporting facility and coverage answers are reported separately, not added to financial risk.
The two figures at the ends of the slider are the smallest and the largest answers this box takes. They mark the edges of the question. Neither one is a typical figure for this plant, and neither one is a suggestion.
$Not set
050,000,000
The remittance advice carries every deduction a customer took back.
Money customers took back after a stoppage, last 12 months. Blank means unknown; zero means none. The selected calculation identifies the financial role. Supporting facility and coverage answers are reported separately, not added to financial risk.
The two figures at the ends of the slider are the smallest and the largest answers this box takes. They mark the edges of the question. Neither one is a typical figure for this plant, and neither one is a suggestion.
Not set
percent of units run
The scrap chart shows how far the rate rose above normal in those hours.
Extra scrap, above the plant's normal rate, during those hours. Blank means unknown; zero means none. The selected calculation identifies the financial role. Supporting facility and coverage answers are reported separately, not added to financial risk.
$per unitNot set
01,000,000
Cost accounting carries the standard cost of the unit where it was scrapped.
Does a USDA-FSIS inspector work in this plant?
Yes means inspectors from the Food Safety and Inspection Service work here.
Does a USDA-FSIS inspector work in this plant?. Blank means unknown; zero means none. The selected calculation identifies the financial role. Supporting facility and coverage answers are reported separately, not added to financial risk.
Is this an FDA-registered human or animal food or beverage plant?
Yes means this plant is registered with the Food and Drug Administration.
Is this an FDA-registered human or animal food or beverage plant?. Blank means unknown; zero means none. The selected calculation identifies the financial role. Supporting facility and coverage answers are reported separately, not added to financial risk.
Is this an FDA-registered drug, biologic or dietary supplement plant?
Yes means this plant makes finished drugs, biologics or dietary supplements.
Is this an FDA-registered drug, biologic or dietary supplement plant?. Blank means unknown; zero means none. The selected calculation identifies the financial role. Supporting facility and coverage answers are reported separately, not added to financial risk.
Is any air handling or ventilation finding still open here?
Yes means an air handling or ventilation finding is still open and dated.
Is any air handling or ventilation finding still open here?. Blank means unknown; zero means none. The selected calculation identifies the financial role. Supporting facility and coverage answers are reported separately, not added to financial risk.
Step 3Describe the equipment serving the line
Can a second cooling unit carry that bay on its own?
Yes means a second unit is on that bay and sized to carry it alone.
Can a second cooling unit carry that bay on its own?. Blank means unknown; zero means none. The selected calculation identifies the financial role. Supporting facility and coverage answers are reported separately, not added to financial risk.
Has that backup started itself under load within 12 months?
Yes means a dated record shows that backup starting itself under load.
Has that backup started itself under load within 12 months?. Blank means unknown; zero means none. The selected calculation identifies the financial role. Supporting facility and coverage answers are reported separately, not added to financial risk.
Is there a quoted lead time for temporary cooling here?
Yes means a rental vendor has quoted a lead time for this bay.
Is there a quoted lead time for temporary cooling here?. Blank means unknown; zero means none. The selected calculation identifies the financial role. Supporting facility and coverage answers are reported separately, not added to financial risk.
hoursNot set
08,760
A datalogger records the hours the line ran outside its process window.
degrees FNot set
A datalogger at the machines carries the hottest reading from last summer.
Hottest reading taken at the machines in that area, last summer. Blank means unknown; zero means none. The selected calculation identifies the financial role. Supporting facility and coverage answers are reported separately, not added to financial risk.
peopleNot set
010,000
The shift roster for that area carries the count.
Everyone who works in that area on a shift. Blank means unknown; zero means none. The selected calculation identifies the financial role. Supporting facility and coverage answers are reported separately, not added to financial risk.
The two figures at the ends of the slider are the smallest and the largest answers this box takes. They mark the edges of the question. Neither one is a typical figure for this plant, and neither one is a suggestion.
shiftsNot set
01,000
The production schedule and the temperature record together carry this count.
Production shifts last year when that area measured 82 F or hotter. Blank means unknown; zero means none. The selected calculation identifies the financial role. Supporting facility and coverage answers are reported separately, not added to financial risk.
The two figures at the ends of the slider are the smallest and the largest answers this box takes. They mark the edges of the question. Neither one is a typical figure for this plant, and neither one is a suggestion.
poundsNot set
020,000
The nameplate on the unit that failed carries its full charge.
Full refrigerant charge in the unit that failed. Blank means unknown; zero means none. The selected calculation identifies the financial role. Supporting facility and coverage answers are reported separately, not added to financial risk.
The two figures at the ends of the slider are the smallest and the largest answers this box takes. They mark the edges of the question. Neither one is a typical figure for this plant, and neither one is a suggestion.
Is that unit charged with an HFC or HFC blend - R-410A, R-134a, R-407C, R-32?
The nameplate names the refrigerant in that unit.
Is that unit charged with an HFC or HFC blend - R-410A, R-134a, R-407C, R-32?. Blank means unknown; zero means none. The selected calculation identifies the financial role. Supporting facility and coverage answers are reported separately, not added to financial risk.
Is that unit charged with an older ozone-depleting refrigerant?
The nameplate says whether the charge is R-22, R-123 or R-12.
Is that unit charged with an older ozone-depleting refrigerant?. Blank means unknown; zero means none. The selected calculation identifies the financial role. Supporting facility and coverage answers are reported separately, not added to financial risk.
Not set
percent of full charge
0500
The service invoices carry the refrigerant put into that unit last year.
Share of that unit's charge added back in 12 months. Blank means unknown; zero means none. The selected calculation identifies the financial role. Supporting facility and coverage answers are reported separately, not added to financial risk.
The two figures at the ends of the slider are the smallest and the largest answers this box takes. They mark the edges of the question. Neither one is a typical figure for this plant, and neither one is a suggestion.
Questions included in this metric
Every question in this panel feeds the figures beside it. Nothing is set aside.
Starting values, blanks and sources
Every box below opens blank, or at a starting value. A starting value stands only until the site's own figure takes its place. It is named under its box, with its source, and with its working one symbol away. A blank box is refused by name until the site answers it. Every box says why behind the information symbol beside its question.
Use the number of similar outages in the result period. Annual records are included once; only repair costs are multiplied by this count. In hourly or per-event records mode, the selected service loss is also multiplied. This is a scenario assumption, not a failure prediction.
events / year
Repair costs to include
Select only costs not already counted above.
Facility and coverage context · optional
These answers support a review. They do not add penalties, assume an insurance payment, or erase a loss already entered.
Save or reopen this scenario
Answers remain in memory until this page closes or reloads. A downloaded file keeps calculator answers only, not contact details. Stored comparison answers are retained even when No onsite spares locks the displayed values to Today. Anyone with the file can read those answers. Older calculator versions cannot be reopened here.
Annual cost todayNot set
Building types and method
Step 1
Which building is this?
This page is built for manufacturing / industrial plant. Choose another building type if needed.
How this is different
Every box opens blank, or at a starting value. A starting value stands only until the site's own figure takes its place. Where CCMS cannot source something honestly, this page leaves it out and names it.
30
Questions, and every one of them this building type's own
All 30 of them sit in the two steps below. Every figure this page prices is already a cost for a year. No count of events in a year is asked. Each one comes off this market's own contract language and its own published rates. A question CCMS cannot source honestly is not asked.
Parts readiness starts with the actual equipment.
Turn the estimate into an equipment conversation
An HVAC Health Assessment reviews one critical asset, its operating condition and available alarm history. The facility team supplies schedule, cost and contract figures; the assessment does not verify every calculator input.
