Automation ROI Tool

What return on investment can you expect from paint line automation?

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
$
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