Electrical Downtime Cost Calculator
Quantify the true cost of terminal block failures, intermittent connector faults, and cable damage on your packaging lines — including MTTR search time.
1 — Line & Production Parameters
Number of packaging lines
lines
Production shifts per day
shifts
Production days per year
days
Production value per hour (per line)
$
/hr
Fully loaded maintenance labour rate
$
/hr
Technicians deployed per fault event
techs
2 — Fault Sources & Frequency
■ Cause 1 — Loose or Failed Terminal Block Connections
Fault events per line per year
events
Avg. total downtime per event
hrs
% of total downtime spent searching (MTTR search vs repair split)
%
Search time
Repair time
■ Cause 2 — Bad Field Connectors & Intermittent Faults
Fault events per line per year
events
Avg. total downtime per event
hrs
% of total downtime spent searching (intermittent faults are hardest to find)
%
Search time
Repair time
■ Cause 3 — Wrong or Damaged Cables (Cable Tracks & Robotic Applications)
Fault events per line per year
events
Avg. total downtime per event
hrs
% of total downtime spent searching (wrong cable spec is often not obvious)
%
Search time
Repair time
MTTR Breakdown — Search vs Repair
Avg MTTR — Terminal Block
—
—
Avg MTTR — Field Connector
—
—
Avg MTTR — Cable Fault
—
—
Total annual search hours (all lines)
—
Labour hours spent looking, not fixing
Total annual repair hours (all lines)
—
Actual fix time once fault located
Annual Fault Summary — All Lines
Total fault events / yr
—
Total downtime hours / yr
—
Total maintenance labour hrs
—
Weighted avg MTTR
—
Cost Breakdown by Fault Type
| Fault Type | Events / yr | Downtime hrs | Production Loss | Labour Cost | Total Cost |
|---|---|---|---|---|---|
| Terminal Block | — | — | — | — | — |
| Field Connector | — | — | — | — | — |
| Cable Fault | — | — | — | — | — |
| TOTAL | — | — | — | — | — |
Annual Production Loss
—
Revenue foregone while lines are stopped
Annual Labour Cost
—
Fully loaded maintenance technician cost
Total Annual Cost
—
Production loss + maintenance labour combined
The Search Tax — What Your Architecture Is Costing You
Annual cost of search time only
—
Labour + production loss during search hours
Search time as % of total cost
—
The portion that better architecture eliminates
Over-Molded Connectorized Architecture Saves Est.
—
Based on 75% reduction in search time with distributed IP67 I/O
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