01
Your industry
02Your companyCollapse
Used for the plausibility check
€M
Whole company
people
Shifts per day, 8 hours each
shifts
Machines that limit throughput
machines
Excluding plant shutdowns and public holidays
weeks
03Your productionAdjust values20 machines · 400 orders/month · 3 planners · OTIF 88%
Machines and equipment in production
machines
Average across all machines
%
Working directly in production
people
Productive time on orders
%
Production orders
/ month
On average
ops
Overtime and extra shifts
€
Planning, process planning, dispatching
people
Delivered on time and in full
%
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How the calculator works
| Area | Calculation |
|---|---|
| 1 · Planning effort | People in planning × annual working hours × planning share × planning hourly rate. The planning share rises with the operations per planner (30 to 85%). |
| 2 · Machine idle time | Machine hours (shifts × 8 h × 5 days × working weeks) × idle share × 30% planning-related × (machines × machine hourly rate + bottleneck machines × contribution margin per bottleneck hour) |
| 3 · Labor idle time | Production staff × annual working hours × idle share × 30% planning-related × production hourly rate |
| 4 · Premium pay | Premium pay per month × 12 × 50% planning-related |
| 5 · Late-delivery cost | Orders per month × 12 × (1 − OTIF rate) × cost per late order |
Assumptions for Machinery & plant engineering: machine €90/h, 3,680 h/year · bottleneck contribution margin €120/h · production €48/h · planning €65/h, 1,720 h/year · 30% of idle time and 50% of premium pay planning-related · €1,200 per late order. All values are examples.