Reliability ROI Calculator
Use this complimentary tool to quantify the business value of closing the gap between your current maintenance performance and industry best-in-class benchmarks.
Financial Parameters
The economic foundation of the calculation — cost of capital, asset value, and per-unit economics.
The cost your company pays to borrow money.
Sometimes termed the internal rate of return — a benchmark that compares projects against expected financial gain. Enter a value between 0.5 and 100.
The cost to procure, install, and commission a replacement plant or equipment.
Also referred to as estimated replacement value. The dollar value required to replace the production capability of the present assets. Excludes the value of real estate or depreciation.
Average sales price per unit produced and sold.
In dollars. The average sales price per unit that your company collects per unit of product produced and sold.
Total cost of a single unit produced.
The cost per unit produced including raw materials and energy used to run machinery.
Sales, marketing, administrative, facility & operator overhead.
Only include operator time to run machinery if available.
Audited book value of maintenance, repair & operating supplies in stock.
Includes consignment and vendor-managed inventory, in all storage locations. Does not include production-related inventory such as raw materials, finished goods, or packaging.
Production Capacity
What your plant is engineered to produce, and what it actually delivered.
Units that your plant can produce at 100% capacity.
The amount of product this plant or unit is engineered to produce at 100% availability.
Actual units produced — by number, weight, or volume.
Measured as a count, weight, or volume over the same period as the engineered capacity.
A year has 8,760 hours of possible availability.
Availability is a measure of when the asset is either running or capable of performing its intended function. Enter a value less than or equal to 8,760.
Maintenance & Reliability
Total maintenance investment and how plant hours are consumed — idle, scheduled, and unplanned.
Includes operator maintenance activities.
All maintenance expenses for outages, shutdowns, or turnarounds, as well as normal operating times. Includes capital expenditures directly related to end-of-life machinery replacement. Does not include capital expenditures for plant expansions or improvements.
Hours an asset is idle or waiting to run.
The sum of hours when there is no demand and administrative idle time (e.g., not scheduled for production). Does not include downtime or no-handclock/no-raw-material conditions. Enter a value ≤ 8,760.
Total hours the asset is down for maintenance or repair.
Scheduled downtime: planned weekly maintenance. Unscheduled downtime: repairs or modifications not on the weekly schedule.
Your Metrics vs. Industry Best-in-Class
Five derived reliability metrics calculated from your inputs, compared against industry best-in-class benchmarks. Mock values shown — wire to Gravity calculation fields in integration.
The annual value of closing the gap between your current maintenance performance and industry best-in-class — achieved through a sustained reliability program, not a single project.
Current Performance
At Best-in-Class
See where Cutsforth can help your operation.
A short conversation with a Cutsforth reliability engineer is the starting point — a chance to review your results and identify how and where you can improve by working with Cutsforth's reliability program experts.
Best-in-class values are derived from Cutsforth's 35 years of reliability work across utility, oil & gas, and process industries, cross-referenced with SMRP and ISO 55000 reliability benchmarks. Results are directional and intended to support reliability program planning conversations.
ROI Calculator - Talk to an Expert
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