What do unlogged issues cost your plant?

Put your own numbers in. See what reporting time, unplanned stops, scrap and chasing actions cost you a year, and a conservative estimate of what better frontline capture could recover.

The figures below are examples. Replace them with your plant’s numbers; results update as you type. Nothing you enter leaves your browser.

Your plant

Production lines in scope

Shifts per day

Operating days a year

Supervisor cost per hour

Fully loaded: salary, employer costs and benefits.

Reporting and follow-up

Minutes per line, per shift, on reports and handovers

Writing the shift report, filling the log, briefing the next shift.

Hours a week supervisors spend chasing actions

Collecting updates, consolidating lists, following up on open items.

Unplanned stops

Unplanned stops per line per day

Average length of a stop, in minutes

Cost of one minute of a stopped line

The margin on output you didn’t make. Siemens puts unplanned downtime in FMCG at around €600 a minute for a whole plant (True Cost of Downtime 2024).

Quality

Scrap and rework cost a year

From your finance or quality reports.

Your estimate

These issues cost you about

– a year

Conservative recovery with better capture

– a year

– supervisor hours a year on reports and chasing actions · – hours of unplanned stops

Breakdown per year

Writing reports and handovers Cost today – Recovery –
Unplanned stops Cost today – Recovery –
Scrap and rework Cost today – Recovery –
Chasing and consolidating actions Cost today – Recovery –

Method

How the estimate works

We’d rather give you a number your finance team believes than a big one they can pick apart. Every range uses the conservative end of published benchmarks, then takes 20% off.

Reporting and handovers

Lines × shifts × operating days × minutes per report, valued at the supervisor rate. Recovery range: 40–70% of that time, the conservative end of what digital shift reporting delivers (Forrester’s study of a frontline operations platform found around half of indirect labour time saved).

Unplanned stops

Lines × operating days × stops per day × minutes per stop × cost per minute. Recovery range: 5–10%, from faster recovery when the cause and history of a fault are already logged. Industry case studies report 20–35% less downtime; we plan on the low end.

Scrap and rework

Your annual scrap and rework cost. Recovery range: 5–15%, from spotting repeat quality losses sooner. Vendor studies report 27–70%; again, we use the conservative end.

Chasing actions

Hours a week × 48 working weeks, valued at the supervisor rate. Recovery range: 30–50%, in line with what plants save when paper and re-keying go digital.

Risk adjustment

Every recovery figure is multiplied by 0.8, the same haircut independent Total Economic Impact studies apply, and rounded to two significant figures. Each lever is counted once: reporting time isn’t also counted as admin, and downtime is valued only through faster recovery.

What’s not included

Avoided safety incidents, faster onboarding and lower turnover. They’re real, but too dependent on the plant to put in a public calculator. We include them in a full business case.

Turn this into a business case

In a demo, we build the full case on your numbers: payback, three-year return, and which line to start the 90-day pilot on.

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