Calculate the true cost of unplanned downtime

See your numbers. Understand your risk. Find your payback.

Based on one Gateway + load sensor. Adjust the sliders to match your shop.

£60/hr
112 hrs
£10,000
£4,300
3 years

Unplanned failure cost (what ID4OS helps you avoid)

Unplanned total

£21,020

Planned intervention

£9,680

Saving per avoided event

£11,340

ID4OS cost over analysis window

Gateway

£450

Pro subscription

£2,700

Total

£3,150

Amounts use your live Pro monthly rate and the lowest catalogue price for a Gateway with one load sensor (Wi‑Fi).

Bottom line (single avoided event)

Net benefit

£8,190

ROI

260%

Payback

3.3 mo

Order a Gateway£450Free Starter plan included. 90-day money-back guarantee—if it's not for you, we make it right.Start freeMonitor one machine on usNo AI diagnostics on the free tier, no card required. Get hardware on the floor first—upgrade to Pro when you're ready.

Proof & detail

Spindle failures don't happen overnight. But the warning signs do appear in the data—often weeks before catastrophic failure.

"One Gateway, one sensor, one caught spindle issue pays for three years of monitoring four times over. And you only need to be right once."

Spindle bearings don't fail overnight. Neither do ballscrews, way lubrication systems, or drive motors — they degrade over weeks, and the load signature changes long before the machine stops. The ID4OS Diagnostic Gateway captures that signature continuously on every axis. The Asset Management Platform flags the change while there's still time to schedule the repair instead of react to it.

What to factor in

  • Unplanned downtime — Average cost per hour of lost spindle time (production value, missed deliveries, overtime to catch up).
  • Emergency maintenance — Call-out fees, rush parts, and collateral damage when a small issue becomes a major failure.
  • Scrap and rework — Material and labour lost when a tool or axis fails mid-cycle.
  • Energy and tool life — Stable loads often correlate with better tool life and more predictable power draw.

Concerned about setup complexity? Your first machine typically takes just a few minutes to install. See the full process.

Questions before you order? Contact us—we respond to real shop problems, not pricing games.

Load Lines Newsletter

Insights on spindle and axis health, failure patterns, and what your load data reveals. For shop owners and maintenance teams who own their uptime.