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Automation ROI Tool
What return on investment can you expect from paint line automation? Calculate your savings.
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
$
