Overview
The cost of downtime in manufacturing continues to climb, with unplanned interruptions hitting U.S. manufacturers hard. Recent Fluke data (2025) show unplanned downtime costs manufacturers up to $207M weekly across the sector. Globally, the world’s largest companies lose trillions annually to these events, which is roughly 11% of revenues in some analyses.
In the U.S., downtime in manufacturing is costly, often exceeding $50 billion per year in total unplanned losses. Hourly figures vary widely by industry and scale, but averages frequently land in the $260,000 range for many operations, with spikes much higher in automotive or heavy industry.
