Improvements
Every fix that moves the factory toward its potential, ranked by what it adds and grouped by root cause, with the math behind each dollar.
Recurring annual operating-profit gain, built from real industry data for a plant like this, plus a separate one-time cash inflow shown below.
Firm
$774K
not gated on anything
Conditional
$120K
needs sales to fill the freed press hours
One-time cash
$555K
from selling idle presses and freeing working capital
Global assumptions
Shared across cards · edits update every number
Every figure on this page recomputes as you type. A value pushed outside its sourced range turns amber and erodes that card's confidence.
Recover hidden press capacity
Clip-on sensors that track uptime (OEE) on every press, then act on the downtime
Financial impact
$120K
EBITDA / yr
Operational impact
~2,200
freed press hours / yr
Capex
$75,000
Payback
7 mo
Difficulty
2 / 5
Confidence
Take the padding out of the cycle
Cooling first, then hot runners on the true high-runners
Financial impact
$72K
EBITDA / yr
Operational impact
~1,000
freed press hours / yr
Capex
$30,000
Payback
5 mo
Difficulty
3 / 5
Confidence
Preventive maintenance on the presses
Run-hour PM plus condition sensors on the worst-breakdown presses
Financial impact
$62K
EBITDA / yr
Operational impact
~700
fewer breakdown hours / yr
Capex
$40,000
Payback
8 mo
Difficulty
3 / 5
Confidence
Cut changeover time with SMED
Stage tooling off-press, quick clamps on the worst-changeover presses
Financial impact
$54K
EBITDA / yr
Operational impact
~30
min faster / changeover
Capex
$22,000
Payback
5 mo
Difficulty
2 / 5
Confidence