Plant ROI simulator
Move the sliders for production, the electricity bill and your breakdown history. The results update instantly, with the formulas and assumptions in plain view and no form to fill in.
Industry
Scenario
The starting values are only a starting point. Replace them with your own.
All three modules
3D digital twin
Pick an area, run a shift or a whole year, then click a machine to see what happens. Every figure follows the simulator settings below.
Bottleneck machines counted
Start with the machines that set the line output. Click the machine tiles to change the count.
Shift pattern
Minutes per shift per machine. Short, repeated stops are rarely logged, yet together they are often the largest loss.
Minutes per shift per machine.
Contribution margin of one hour of line output, not the selling price.
Hours a month compiling reports from spreadsheets.
Simulation results
Recoverable in this scenario
A projection from your own figures and assumptions, not a promised result. The real numbers are measured during the pilot.
Your existing PLCs
Siemens, Mitsubishi, Omron, Allen-Bradley
Industrial edge gateway
Modbus, OPC UA, MQTT
Server in your plant
Data stays on the plant network
TNS
OEE, production, energy
Pilot starting scope: 6 measuring points, 6 bottleneck machines on one line.
No PLC needs replacing. The final point count is confirmed during the site survey.
Download a two-page business case with the figures, assumptions, formulas and the pilot design from your simulation.
Three quick details, then the file downloads straight away.
Method
Every figure comes from a formula you can check yourself. It is the same framework we use in the assessment with your plant team.
Hours recovered = annual stoppage hours × recovery factor
OEE is calculated from availability, performance and quality. Lost time is broken down by cause, so you can see how much comes from stops, speed and defects. Recovered hours are valued as capacity, not cash.
What OEE is and how to calculate itCash saved = annual spend × asset share × waste reduction
The largest waste usually comes from machines left running while nothing is produced and load piling up in peak-tariff hours. This is the only result that cuts spending directly.
How to cut a plant’s electricity billExposure = breakdowns × (MTTR × stoppage cost + emergency cost)
An emergency repair costs more than a planned one because the line stops without warning and parts are bought in a hurry. Losses avoided are the share of that exposure that can become planned work.
How to calculate MTBF and MTTRWhy it is not a promise
The percentages behind the conservative, moderate and optimal scenarios are starting assumptions you can change, not results we have measured at your plant. We deliberately do not publish savings figures we cannot prove.
We keep three kinds of result apart because Finance reads them differently. Cash savings reduce spending. Freed capacity is only worth something when there are orders. Losses avoided are risk that goes down.
The real numbers are measured in a pilot on one line or a few critical assets, against a baseline recorded before the system goes live.
After the simulation
01
Simulation
You enter your plant figures and take the business case to your internal meeting.
02
Assessment
Our engineer reviews the data, signal sources and network with your team.
03
Pilot
One line or a few critical assets are connected, and a baseline is recorded before go-live.
04
Expansion
Pilot results are compared with the baseline before more lines are added.
Multiply the stoppage minutes per shift by the shifts, the working days and the number of machines, then divide by 60 to get the stoppage hours a year. Multiply those hours by the contribution of one hour of output. The simulator above does this and separates the share that is realistic to recover.
Cash savings reduce spending, such as the electricity bill. Freed capacity is production time that becomes available again, and it only turns into money when there are orders to fill it. The two are deliberately never added together.
They are starting assumptions to open the discussion, not results measured at your plant. Open "View and edit assumptions" to change them. The real results are measured during the pilot against a baseline recorded first.
No. The calculation runs in your browser. We only receive your simulation figures if you fill in the form to download the business case, so our engineer reads the same scenario you did.
No. Data is read from your existing PLCs and meters over Modbus, OPC UA or MQTT. Wireless sensors are added only to assets that have no signal yet.
It depends on the number of measuring points, the signal sources, and whether the server runs on-premise or in the cloud. We price it after the assessment, from the pilot design in your simulation.
Send your simulation to our engineers. We go through the data sources, measuring points and how the results will be measured during the pilot.
