Graco Inc.
Header

Labor

Before Automation

After Automation

Painters per shift
Number of shifts
Hours per shift
Labor rate per hour including healthcare and benefits
$
$
Working days per year
Overtime premium expense per year
$
$
Worker Preparation (hours per year)
Worker Training, Meetings, and Downtime (hours per year)
Cost of managing painters (% of time x salary)
$
$

Process Improvement

Parts per hour
Productivity improvement (increased line speed, reduced downtime)
%
Parts per year

Materials, Solvent, and Consumables

Paint and solvent consumption per year
$
$
Waste disposal expense per year
$
$
Booth filtration, waste water, and other consumables
$
$
Material efficiency improvement with automation (typically 15-30%)
%
Worker personal protection equipment cost
$
$

Quality

Rejected Parts Per Year
Reject rate improvement
%
Average rejected part cost
$
$
Cost to scrap or rework per part
$
$
Scrap and Rework Cost Total
$
$
Warranty expense due to poor paint quality
$
$

Summary

Total labor cost per year
$
$
Total material and consumable cost per year
$
$
Labor cost per part
$
$
Material cost per part
$
$
Total cost per part
$
$

Equipment

Automation Equipment Investment
$