Line Stoppage Cost Report
Your assembly line doesn’t stop because of a big machine failure. It stops because a small bin is empty.For heavy machinery, every hour of stoppage means idle manpower, delayed FG, and penalty on delivery. Yet most plants have never calculated the real cost.This quick report helps you see the number — and how efficient SCM with near-plant warehousing, VMI, and JIT line-feed fixes it.
Your Quick Cost Calculator
Use your last month’s data:
|
|
What to fill
|
Your Number
|
|---|---|---|
|
Avg. assembly output value per hour (Rs.)
|
[Text Field]
|
|
|
B
|
Idle manpower + overhead per hour (Rs.)
|
[Text Field]
|
|
C
|
Avg. stoppage hours due to part shortage per incident
|
[Text Field]
|
|
D
|
No. of such incidents last month
|
[Text Field]
|
|
E
|
Your Monthly Loss = (A+B) x C x D
|
Auto-calculate
|
Note: Most fabrication units we audit lose 12-25 hours/month. At Rs. 15,000/hr combined cost, that's Rs. 1.8L - 3.75L/month in hidden loss.
Where Efficient SCM Saves That Money
|
VMI - Pay As You Consume
|
JIT Line-Feed - No Searching
|
Procurement & QC at Source
|
|---|---|---|
|
Parts come as kitted trolley, sequenced per your BOM, at shift time. Fitter picks, not searches. Handling time down by ∼18%.
|
Vendor identification, negotiation, drawing-based QC before stock enters WMS. Rejected lots never reach your bay.
|
Download Your Free Report + Get Your Plant Score
What You Get in This Report
-1-page PDF calculator you can share with your Plant Head
- Benchmark: What good plants achieve (OTIF >99%, Stock 99.5%)
- Checklist: Is your store feeding the line JIT? (5 yes/no)
- Next step: Free 15-min stock audit for top 20 critical spares
FAQ - Quick Questions
Is this report free?
Yes, and it will remain free. We use it to audit your plant's top losses.
Do I need to share sensitive data?
No. Just avg. values. We calculate range, not exact P&L.
What after download?
You get PDF + optional call to map VMI & JIT for one bay as pilot
One hour of stoppage = one hour of lost machine. Let's make your line wait less.
