Free, no email required
Price it yourself before you call anyone.
Four calculators that take figures you already have and put a number on something your books are quiet about. Each one runs in your browser, nothing is sent anywhere, and every one of them prints to a single page you can take into a meeting.
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What an idle hour costs you
Six figures you already know, and you get what an hour of unplanned downtime costs this line, per hour and per year. The one to start with if you have never put a number on downtime.
Open the downtime calculator -
What a scrapped part actually costs you
Your system values scrap at standard cost. This prices what standard cost cannot see: the rework labor, the sorting and containment, and the overtime premium paid to make the replacement. Works on a component or a finished assembly.
Open the scrap and rework calculator -
What your changeovers cost you
Unplanned downtime gets investigated. Changeover time gets scheduled, so nobody questions it. This prices the hours, then shows what cutting them by twenty, thirty or fifty percent would be worth.
Open the changeover calculator -
How much more you could sell before buying anything
A line that is full at eighty percent is not the same as a line that is full. Sitting next to a quote for another machine or another building, this prices the hours already inside the asset you own.
Open the capacity calculator
How to read what they give you
They are built to be argued with. Each one states what it counts, what it deliberately leaves out, and where it may be overstating. The figures are floors rather than ceilings, because a number that survives a controller is worth more than a number that impresses a room.
They price one line or one part, not the plant. A thirty five dollar part and a four hundred dollar part blended together produce a number that describes neither, so none of them average. Run one twice for two lines and keep both sheets.
Do not add the results together. They look at overlapping hours from different angles. A changeover that ran long may already sit in your downtime log, and the capacity tool prices the same hours the other two do. Each tool says where it overlaps.
One line priced is not a plant priced.
These tools answer one question at a time, which is exactly what a free tool should do. Working out where the money actually sits across the whole operation, and which two or three things to go after first, is what the audit is for.
How the audit worksGot a number you did not expect?
Send it to me. I will tell you whether it looks right, what I would check next, and whether it is worth doing anything about.
chad.rauch@cr-dynamics.com
630-402-6680