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AOG Downtime Cost Calculator

The full cost of an aircraft-on-ground event: lost revenue, crew and parking, parts and shipping — per day and total.

AOG economics justify decisions that look extravagant in isolation — overnight freight, loaner units, premium labour — because the downtime usually costs more than the cure.

30,700 $
Total AOG cost
5,117 $/day
Cost per day down

Run the same numbers for the alternative (overnight part, loaner unit, premium labour) — the comparison is the decision.

With your numbers: 6 days down at 3,200/day revenue plus 450/day in crew and parking, with 8,200 in parts and 600 shipping, totals 30,700 — 5,116.67 per day.

⚠️ Not for operational decisions. This is a record-keeping and planning aid only — not certified avionics, not a source of regulatory truth. Always verify against official sources (FAA) and your operator's approved documents before flying.

Disclaimer: This tool is for general informational and estimation purposes only and is not professional financial, tax, accounting or legal advice. All figures are estimates — verify with a qualified professional before making decisions. Read the full disclaimer.

Free AOG cost calculator: lost revenue, daily holding costs, parts and freight in one total — the number that turns 'expensive overnight shipping' into the obviously cheap option.

About AOG Downtime Cost Calculator

An aircraft on ground bleeds money through channels the maintenance invoice never shows: cancelled revenue, crew repositioning and per-diems, parking at an away station, customers who book elsewhere next time. Operators who quantify the full daily burn make systematically different — and better — decisions: the $900 overnight freight against a $3,600/day burn approves itself, as does the loaner exchange unit, the premium weekend labour, the mechanic flown in. This calculator assembles the honest total: days down, revenue and holding costs per day, parts and shipping. Run it for the event you're in, then run it for each alternative recovery path; the comparison usually makes the decision, and the per-day figure makes a permanent case for the spares and tracking discipline that prevent the next one.

How to use AOG Downtime Cost Calculator

  1. 1Enter days down and the honest per-day revenue and holding costs.
  2. 2Add parts and expedited shipping for this recovery path.
  3. 3Re-run for each alternative path; pick the cheapest total, not the cheapest invoice.

Why use AOG Downtime Cost Calculator?

  • Full-cost framing: revenue, holding, parts, freight — not just the invoice
  • Per-day burn rate prices every recovery alternative instantly
  • Justifies (or kills) expedited options with arithmetic instead of instinct
  • Builds the business case for spares and maintenance forecasting
  • Instant, free, browser-only

Frequently asked questions

What's a realistic lost-revenue figure per AOG day?+

For revenue aircraft: average daily billings over the trailing month (charter revenue, instructional rentals, tour seats), minus only the costs that genuinely stop (fuel). For private/business use, price the disruption honestly — airline tickets bought, meetings missed, the trip that didn't happen. Zero is almost never the true number, and using zero is how operations talk themselves into week-long groundings to save a freight bill.

When does expedited shipping pay for itself?+

Whenever its premium is less than the days it saves times your per-day burn — which at any meaningful utilisation is almost always. A $700 overnight premium against a $2,500/day burn pays for itself in seven hours of saved downtime. The calculator's per-day output exists to make this a ten-second check; operations that run it stop having the freight argument entirely.

How do I use AOG math to justify spares inventory?+

Price one prevented event: if a $4,000 starter-generator on the shelf converts a three-day AOG into a two-hour swap even once, it returned multiples of its carrying cost. List your historical AOG causes, price each at your per-day burn, and the rational spares list writes itself — usually ignition, fuel-system and landing-gear consumables first. The same math funds maintenance forecasting tools and tracking discipline.

Why doesn't this tool sync to the cloud?+

By design: operational records are sensitive, and the simplest privacy guarantee is never transmitting them. Local-only storage means zero servers, zero breach surface and zero subscription. If you work from several devices, keep one as the master record and move snapshots with the CSV export.

Can I export these records for an audit?+

Yes — one click exports your complete AOG analysis as a CSV file that opens in Excel, Google Sheets or Numbers. The export preserves every column exactly as entered, so you can print it, attach it to paperwork, or hand it to an inspector, buyer or insurance underwriter as a supporting summary alongside your official records.

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