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
- Every assumption editable
- Downloadable PDF report
Your plant
Assumptions · edit to match your plant
Improvement ranges from the KaizenFlow design-partner model: downtime 8-18% · scrap 5-12% · throughput 4-11% · energy 3-7%
Modeled annual savings, midpointCustom assumptions
$2.4M
Range: $1.3M to $3.4M a year
About $199K for every month improvements wait
- 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
Free review · one business day response
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.
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Thanks. We respond within one business day at the email you gave us. In the meantime, keep a copy of your report.
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. Nothing is sent to KaizenFlow unless you submit the review form. Share links carry your numbers and the report name, nothing else, and our site analytics are cookieless.
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.