Your numbers, not ours
What is downtime actually costing you?
Plug in your own plant. The improvement assumptions below are deliberately conservative — the pilot's whole job is to beat this case.
Footprint
Downtime
Scrap
Changeovers
Conservative improvement assumptions
Adjustable — these are deliberately modest.
What it's costing you
Losses, per week
$0
downtime $0 · scrap $0 · changeover $0
Losses, per year
$0
Conservative savings, per year
$0
Spall cost, year one
$0
Net, year one
$0
ROI multiple
0x
Payback
0 wks
These are your numbers — the pilot's job is to beat this conservative case.
Book a pilot →Spall · ROI worksheet
Your numbers, and the math behind every one.
Every figure above is computed live from the values you entered — no black box. 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) + max(machines × per-machine tier × 12, $12,000 floor). Tiers: $150/machine (≤10), $120 (11–25), $100 (25+).
= ( × $1,500) + max( × × 12, $12,000) =
Net · ROI · payback
net = savings − cost · ROI = savings ÷ cost · payback = cost ÷ savings/wk
net = · ROI = · payback =
Honest caveat: the loss inputs and improvement percentages above are the calculator's conservative defaults unless you changed them — they are not measured from your plant. The pilot replaces every one of these with numbers read off your own machines; its whole job is to beat this case.
This calculator uses the same loss formulas as the Spall pricing model (weekly downtime = machines × hours × rate; scrap = machines × throughput × scrap rate × part cost; changeover = lines × count × minutes × rate) and the published tiered pricing — $150/machine (≤10), $120/machine (11–25), $100/machine (25+), floor $12,000/yr, plus a $1,500 hardware kit per line.