What could digital work instructions save your plant?
Slide to match your situation. You instantly see annual savings, payback time and three-year ROI. Request the report with all assumptions afterwards.
ROI calculator
Step 1 of 4Which industry are you in?
We fill in typical values. You adjust them next.
Unsure about the assumptions? Check them with an expert.
In 30 minutes we look at your process, your numbers and the fastest route to a measurable pilot. No sales pitch, just concrete advice.
Four savings, each with its own formula. No black box.
Faster training
Defaults €40 and €60 per hour.
Fewer errors and scrap
Includes rework, scrap and complaints.
Less downtime
Only downtime caused by SOP errors.
Fewer expert visits
Optional: remote support instead of travel.
Payback, ROI and net present value
- Annual savings = sum of the four savings at full adoption.
- Adoption: 60% in year 1, 80% in year 2, 100% in year 3.
- Net per year = savings × adoption − annual cost. Start = − one-time cost.
- 3-year ROI = (3-year savings − 3-year costs) ÷ 3-year costs.
- Net present value: yearly net discounted at 8%.
- Payback: the point where cumulative cash flow reaches zero, linear within the year.
Impact levels in the quick estimate
| Level | Fewer errors | Shorter training | Less downtime |
|---|---|---|---|
| Conservative | −30% | −25% | −25% |
| Typical | −50% | −40% | −40% |
| Ambitious | −70% | −50% | −50% |
Formulas per use case
- Error-free assembly
- assemblies × (error rate today − with ActARion) × cost per error
- Changeovers (SMED)
- changeovers × minutes saved × cost per minute + changeovers × start-up scrap avoided
- AR-guided maintenance
- unplanned downtime hours × reduction × cost per hour + emergency visits × 50% × cost per visit
- Fault recovery with remote expert
- incidents × (MTTR today − with remote expert) × cost per hour + visits × 60% × €1,500
- Onboarding and training
- new operators × training hours saved × (operator + trainer rate) + new operators × €300 less scrap
Default values (Other manufacturing, Typical)
| Input | Default |
|---|---|
| Operators working with SOPs | 25 people |
| New operators per year | 6 people |
| Training time per new operator | 24 hours |
| SOP executions | 400 per operator/year |
| Error rate today | 3.0% |
| Cost per error | €250 each |
| Downtime from SOP errors | 40 hours per year |
| Cost of one hour of downtime | €2,000 per hour |
| Annual cost | €29,000 per year |
| One-time cost | €25,000 |
Worked example with the default values
- Faster training: 6 × (24 × 40%) × (€40 + €60) = €5,760
- Fewer errors and scrap: 25 × 400 × 3% × 50% × €250 = €37,500
- Less downtime: 40 × 40% × €2,000 = €32,000
- = €75,260 · Payback 15 mo · 3-year ROI 61% · Net present value €53k
Assumptions: adoption 60% in year 1, 80% in year 2, 100% in year 3; discount rate 8%. This is an estimate, not a quote.
Frequently asked questions
Why does the calculator not show prices?
Costs depend on sector, use cases and number of users. We discuss them in a free intake.
Which reduction percentages should I use?
Start conservatively and replace them with your measured pilot KPIs.
Can I include safety benefits?
Yes, as a separate qualitative line. Fewer incidents are valuable but hard to price.
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