How Much Does Industrial Downtime Cost Per Hour?
Unplanned downtime is one of the most expensive and underestimated risks in industrial operations.
​
For many UK manufacturers and industrial facilities, the cost of downtime is not just lost production, it includes labour inefficiencies, delayed orders, wasted materials, and long-term reputational damage.
​
Understanding the real cost of downtime is the first step towards reducing it.
What Is Industrial Downtime?
Industrial downtime refers to any period where production or operations are stopped due to equipment failure, system faults, or maintenance issues.
​
This includes:
-
PLC or control system failures
-
Electrical faults in control panels
-
SCADA or system monitoring issues
-
Mechanical or process breakdowns
​
Downtime can be planned or unplanned, but it is unplanned downtime that creates the greatest financial and operational impact.
The Real Cost of Downtime Per Hour
The cost of downtime varies by industry, but even conservative estimates show significant impact.
​
Direct costs
-
Lost production output
-
Idle labour costs
-
Wasted raw material
​
Indirect costs
-
Missed delivery deadlines
-
Contract penalties
-
Reduced customer confidence
​
Hidden costs
-
Increased maintenance pressure
-
Overtime and emergency repairs
-
Long-term equipment damage
​
In many industrial environments, downtime can cost thousands to tens of thousands of pounds per hour.
The Cost of Industrial Downtime Visualised
Industrial downtime is more expensive than most operations realise, and it rarely comes from a single failure.
In this video, we break down the true cost of downtime in industrial environments, from lost production and labour inefficiencies to maintenance delays and safety risks.
Common Causes of Industrial Downtime
Downtime is rarely caused by a single issue. It is often the result of multiple system weaknesses.
​
Control system failures
Outdated or poorly maintained PLC systems can fail unexpectedly.
See when to upgrade your systems:
/insights/when-to-upgrade-plc
​
Poor control panel design
Unstructured layouts, unclear labelling, and inconsistent wiring make fault finding slow and difficult.
Explore our control panel design approach.
Lack of system visibility
Without SCADA or monitoring systems, faults go unnoticed until failure occurs.
​
Obsolete components
Unsupported hardware increases risk and reduces reliability over time.
What High-Performing Operations Do Differently
Standardised control systems
Consistent design across sites improves maintenance efficiency and reduces risk.
​
Clear documentation
Accurate drawings and structured designs make fault finding faster.
​
Proactive maintenance
Using data and monitoring systems to detect issues before failure.
​
Modern automation systems
Upgraded PLCs and SCADA platforms improve reliability and performance.
​
How to Reduce Downtime in Industrial Systems
Reducing downtime requires a structured, long-term approach.
​
Improve system visibility
Implement SCADA and monitoring systems to gain real-time insight.
​
Upgrade obsolete systems
Replace ageing PLCs and unsupported hardware before failure occurs.
​
Improve panel design and layout
Ensure control panels are built for clarity, accessibility, and maintainability.
​
Standardise across operations
Reduce complexity by using consistent systems and documentation.
Talk to Stratos About your Downtime Issues
Stratos Control Systems help industrial organisations reduce downtime through structured automation design, system upgrades, and improved visibility.