Your own numbers
What is downtime actually costing you?
Plug in your own plant. The improvement assumptions below are conservative by default: the pilot's whole job is to beat this case.
Your plant, in three numbers
Your best guess is fine. You can refine every assumption below.
Estimated annual savings
$0
An estimate from your own numbers, conservatively. Not a guarantee.
Payback
0 wks
First-year net
$0
Want this result emailed to you?
Footprint
Scrap
Changeovers
Conservative improvement assumptions
Adjustable: these are modest by default.
Detailed loss breakdown
Losses, per week
$0
downtime $0 · scrap $0 · changeover $0
Losses, per year
$0
Spall cost, year one
$0
ROI multiple
0x
Spall · ROI worksheet
Your numbers, and the math behind every one.
Every figure above is computed live from the values you entered. Here is the formula behind each number, with your current inputs plugged in.
Downtime loss / week
machines × downtime hrs/machine/wk × downtime $/hr
= × hr × /hr =
Scrap loss / week
machines × parts/hr × (hrs/shift × shifts/day × days/wk) × scrap % × cost/part
= × × hr × × =
Changeover tax / week
lines × changeovers/line/wk × (avg changeover min ÷ 60) × downtime $/hr
= × × ( min ÷ 60) × /hr =
Losses / year
(downtime + scrap + changeover) × 52 weeks
= × 52 =
Conservative savings / year
(downtime × cut% + scrap × cut% + changeover × cut%) × 52
= ( × + × + × ) × 52 =
Spall cost / year one
(lines × $1,500 kit, install day included) + machines × per-machine tier × 12. Tiers: $200/machine (first 10), $160 (11+). 25+ machines: volume pricing, talk to us (the calculator uses $160). Machines sensed by clamp or analog only run $125 flat. Plant minimum $750. Every deployment starts with a credited pilot.
= ( × $1,500) + × × 12 =
Net · ROI · payback
net = savings − cost · ROI = savings ÷ cost · payback = cost ÷ savings/wk
net = · ROI = · payback =
The loss inputs and improvement percentages above are the calculator's conservative defaults unless you changed them, not numbers measured from your plant. The pilot replaces every one of these with numbers read off your own machines, and its whole job is to beat this case.