Savings calculator

What Edmund saves for your plant.

What this doesn't count yet Uptime only. Implementation layers eight more lines on top, from your real maintenance data.

During implementation, against your maintenance database, we add to the headline figure:

A / B / C asset split — buffers that demote an A line to B during a fault
Fixed costs on idle — depreciation, rent, energy that keeps running on a stopped kiln
Catch-up cost — overtime, weekend shifts, premium energy to recover the plan
Operators waiting — loaded cost of people standing next to a stopped line
Reactive maintenance hours — techs, supervisors, technologists pulled off planned work
External service & expedited spares — emergency callouts, freight, premium parts
Quality losses — scrap and ramp-up after every restart
OTIF & penalties — delivery risk to key accounts

/01 Critical machines

Machines and assets that are critical for your manufacturing process.

/02 Reactive downtime per machine

Unplanned hours per year, per machine. Typical: 150–400.

400h / year

50 h 400 h 750 h

/03 Value of one hour of downtime

Lost margin per hour when the line stops — not operating cost. Tap an industry to seed a typical value, then fine-tune.

€1,000/ h

€500 €10,000 €30,000

Choose your industry

What goes into the value of one hour

Three cost streams feed one downtime hour.

Machine downtime hour

× downtime hours / year

Lost margin — contribution that disappears while the line is stopped
Idle production — wages of operators waiting next to a stopped line
Repair & recovery — spare parts, service, scrap material
Overhead & fixed costs — depreciation, rent, energy, admin

Maintenance work hour

× reactive maintenance hours / year

Technician hourly wage — loaded cost of the person on the fault
Maintenance overhead — hourly cost of maintenance capacity (tools, vehicles, planning)

Other annual costs

accumulated / year

External service & spare-part logistics — emergency callouts, freight
Commercial impact — OTIF, contractual penalties
Quality losses — scrap and ramp-up after every restart

Built into the equation from your maintenance database during implementation.

Sources

Siemens — The True Cost of Downtime 2024 Aberdeen Strategy & Research ABB — Value of Reliability MaintainX — State of Industrial Maintenance 2024

/04 Maintenance team hours saved

How the recovered downtime spreads across your maintenance team.

Maintenance technicians

Total team time recovered: 520 h / year
Per technician: 52 h / year — 10 people, from 5 machines × 400 h × 26%

Want the real number?

This is back-of-envelope. The accurate ROI is calculated during implementation, against your maintenance database, your fault counts, your catch-up cost.

Get the real number See a deployment