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Downtime costs 60% of manufacturers over $250K per year...
Every manufacturer knows downtime hurts. But our latest research shows just how costly it really is and why the issue goes deeper than broken machines.
In partnership with a third-party research firm, L2L surveyed over 600 manufacturing leaders across the U.S. to better understand downtime:
On average, facilities lose 30 hours of production per month to downtime. That’s 360 hours per year. And the majority of those hours come from unplanned stoppages.
In fact, 6 in 10 leaders say these disruptions cost their businesses more than $250,000 annually.
While some downtime is planned—think preventive maintenance, inspections, and changeovers—most reported downtime events are unplanned. Breakdowns, minor stoppages, material shortages, to name a few, account for stoppages not factored into production schedules.
But the data shows the real problem isn’t just equipment. It’s systemic.
Downtime doesn’t just hit the balance sheet. More than half of leaders said slowdowns prevent them from hitting production and shipping targets. Others reported frustration, lower morale, and even declining product quality as a result.
Many manufacturers are experimenting with strategic fixes, from stronger maintenance protocols to real-time data visibility. However, most agree that the real solution lies in solving systemic operational problems and connecting people, processes, and data.
Downtime reduction is one of the highest-ROI investments manufacturers can make. And the companies that move from reactive to proactive operations will gain a lasting competitive edge.
👉 Download the full report to see all the data, insights, and recommendations for maximizing uptime in today’s manufacturing environment.
Original version: 8 October 2025
Written by: Evelyn DuJack
Reviewed by: Stephanie Fornino
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