The True Cost of Unexpected Factory Downtime (And How to Prevent It)

1. The Iceberg Principle of Unplanned Stoppages When a production line halts without warning, most plant managers instinctively calculate the loss using a single metric: Lost Production Value = Units per Hour × Selling Price × Downtime Hours. While this figure is alarming enough, it represents only the visible tip of the iceberg. The true…