Free savings calculator

What could KaizenFlow save your plant?

Enter four numbers you already know. The model estimates recoverable downtime, scrap, throughput, and energy savings, shows every assumption, and turns the result into a report you can download and share with your team.

No email required
Runs in your browser
Editable assumptions
Downloadable PDF report

Your plant

Facilities

Annual revenue per facility

Unplanned downtime per facility, per month

Scrap rate

Assumptions · edit to match your plant

Your cost of one downtime hour ($, optional)

Production hours per facility, per year

Margin captured per recovered downtime hour (%)

Margin on added output (%)

Energy spend (% of revenue)

Scrapped output valued at (% of selling price)

Count throughput gain. Untick this if you cannot sell more than you make today.

Improvement ranges from the KaizenFlow design-partner model: downtime 8-18% · scrap 5-12% · throughput 4-11% · energy 3-7%

Modeled annual savings, midpoint

$2.4M

Range: $1.3M to $3.4M a year
About $199K a month at the modeled midpoint

Downtime recovery8-18% of unplanned downtime hours: $546K$336K to $756K
Scrap reduction5-12% less scrap: $383K$225K to $540K
Throughput gain4-11% more output: $1.4M$720K to $2.0M
Energy optimization3-7% less energy spend: $113K$68K to $158K

Gross modeled savings before software or pilot cost. Not a quote or a guarantee. How each figure is calculated

Your savings report

Company or plant name for the report (optional)

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Have us check the math

Send us your estimate. We will look at your inputs, flag any assumption that looks off for your operation, and tell you honestly whether a pilot could prove the savings.

Your estimate is attached automatically, so there is nothing to retype.
We point out the assumptions most likely to be wrong for your plant.
You get a straight answer on whether a pilot can prove it.

Attached to your request

No black box

Every figure, shown in full

The model is deliberately simple so you can check it by hand. Your downloaded report repeats this arithmetic with your own numbers filled in.

8-18% recovered

Downtime recovery

downtime hours per month × 12 × facilities × value of a downtime hour × 8-18%

A recovered hour is worth the revenue it produces times the margin captured (defaults: 6,000 hours a year, 35%), or your own cost of downtime if you enter one.

5-12% less scrap

Scrap reduction

revenue × scrap rate × scrap valuation × 5-12%

Scrap is valued at selling price by default. Lower the valuation to count material and labor cost only.

4-11% more output

Throughput gain

revenue × margin on added output × 4-11%

Only real if you can sell what you make. If demand is your constraint, switch this lever off.

3-7% less energy

Energy optimization

revenue × energy share of revenue × 3-7%

Energy spend defaults to 1.5% of revenue. Replace it with your utility bill as a share of revenue.

Revenue means annual revenue per facility times facilities. The improvement ranges are illustrative model outputs from the KaizenFlow design-partner program, not audited results, guarantees, or live telemetry. Individual results vary by facility, baseline, product mix, and execution.

Questions

Before you share it

Is this a quote or a guarantee?

No. The calculator prints gross modeled savings from your inputs and the assumptions shown. It does not subtract software or pilot cost, and it is not a promise of performance. Use it to size the opportunity, then let a pilot replace it with measured numbers.

Where do the improvement ranges come from?

They are modeled ranges from the KaizenFlow design-partner program: 8-18% less unplanned downtime, 5-12% less scrap, 4-11% more throughput, and 3-7% less energy. They are illustrative model outputs, not audited results, and individual results vary by facility, baseline, product mix, and execution.

Why is throughput usually the biggest line?

Because it applies to all of your revenue rather than to a single loss. It only turns into money if you can sell the extra output. If demand is your constraint rather than capacity, untick throughput in the assumptions and the total falls back to the three cost levers.

Does anything I enter leave my browser?

No. The math and the PDF report are both produced on this page, and nothing you type is sent to KaizenFlow unless you submit the review form. Share links carry your numbers and the report name so a colleague can reopen the estimate. Our cookieless analytics count visits and button clicks without your numbers or names.

What does a pilot cost?

$25,000 to $75,000, fixed. Where you land is set by scope, meaning how many lines and connectors are baselined, and it is agreed before kickoff with no usage-based surprises.