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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:
- Its root causes
- Its impact on business performance
- What companies are doing about it
The high price of 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.
Why it happens
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.
- 67% of respondents admit their companies still rely on reactive maintenance.
- 74% say delays in reporting problems trigger chain reactions across operations.
- 72% acknowledge “hidden factories” of undocumented fixes that mask true downtime.
The ripple effect of downtime
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.
The path to greater productivity and profitability
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.
Revisions
Original version: 8 October 2025
Written by: Evelyn DuJack
Reviewed by: Stephanie Fornino
Please read our editorial process for more information
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