Put a number on what your plant's hardest problems cost each year. The values below are illustrative starting points. Replace them with your own; every benchmark offered is sourced and dated.
Starting value: ABB's reported 2023 median cost of one unplanned outage hour, all sectors.1 Your own margin is the better number. In a batch plant, use batch margin divided by batch hours.
69% of surveyed maintenance decision-makers report an unplanned outage at least monthly.1
In refining and petrochemicals, transient operations are under 10% of operating time yet carry an outsized share of process safety events and major losses.2
A Merck senior director put a failed biologics batch at "often greater than $1 to $2 million" (2008).3 Count a batch here or under downtime, never both.
Nothing here is a guarantee. These are the costs of the events themselves, computed from your inputs.
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