OT downtime costs. But have you ever calculated exactly what?

What does this mean in numbers?

This is a question that management decision-makers rightly ask. The answer is rarely complex – it only requires the willingness to openly calculate the actual costs of non-investment.

The cost of unplanned OT downtime

Direct costs

The direct costs include:

• lost production capacity
• scrap from batches that have already started
• additional work for recovery
• costs for external service providers

Industry studies show:

• In the automotive sector, values of up to 22,000 euros per minute are mentioned
• In discrete manufacturing: 5,000 to 15,000 euros per hour

Indirect costs

• delivery delays
• contractual penalties
• damage to customer relationships
• reputational losses
• increased stress in the maintenance team with effects on error rates and fluctuation

Compliance costs without structured OT management

• high NIS2 penalties
• costs for manual audit preparation
• liability risks for management

Where eguide4DATA creates concrete savings

Shorter downtime through fast restore

If the restore process is structured, the search for the correct backup version is eliminated. Enormous time savings per incident – multiplied by the frequency of incidents – quickly result in five-figure annual values.

Avoidance of subsequent errors through uncontrolled changes

Unversioned, undocumented changes to PLC programs are a frequent cause of later failures. Structured versioning directly reduces this source of error.

Efficiency gains in audit preparation

Instead of several hours of manual preparation: audit reports at the push of a button.

Reduced dependency on individuals

If OT knowledge is no longer only in the heads of individual employees, the following decreases:

• the risk of critical bottlenecks
• the need for external emergency service providers
• the associated costs significantly

Conclusion

The question is not:
“What does eguide4DATA cost?”

But:
“What does the status quo cost?”

Companies that view OT management as an investment regularly underestimate the costs of inaction:

• downtime
• compliance efforts
• knowledge risks

Curious what OT downtime really costs your company?

Experience eguide4DATA in a live demo and see,