Andon System ROI Calculator

Production Days per Week

Working Hours per Day

Number of Machines or Stations

Lines, cells, or workstations requiring support calls

Downtime Cost per Hour ($)

Lost revenue per hour when a station is idle

Avg. Wait Time per Station per Day (min)

Minutes operators spend waiting for support each day

Estimated System Cost ($)

Typical pilot: $5,000–$15,000 for 10–20 stations

Expected Improvement (%)

Reduction in idle/wait time due to faster response

Estimated Annual Savings

0 days

Payback Period

First-Year ROI

Based on real implementations. Most plants see measurable improvements within the first week.

What These Numbers Mean

The calculator estimates savings by applying the improvement percentage to total potential downtime cost across your stations. Real-world results depend on your current response times, the types of support calls your operators make, and how effectively escalation rules are configured.

40%

Average response time reduction reported by existing customers

10–12%

Typical downtime reduction in manufacturing environments

48 hours

Time to first actionable Pareto data after deployment

< 45 days

Typical payback period — often achieved before trial ends

How Savings Are Calculated

Every time an operator waits for maintenance, quality, or materials support, production capacity is lost. An Andon system reduces this wait time by:

Instant notification — alerts reach the right responder in under 1 second via wearable pagers
Automatic escalation — unanswered calls notify a backup, then a supervisor
Data visibility — Pareto charts reveal the biggest time-wasters so you can fix root causes
Accountability — response time is logged, creating a feedback loop that drives improvement

The "15% typical improvement" default reflects conservative results from plants that implement basic escalation rules. Plants that actively use the data for continuous improvement events regularly achieve 25%+ improvement.

See real results in your plant

Start a 60-day free trial with full equipment, training, and setup support. No cost, no commitment — return everything if you're not satisfied.

Explore Andon System

Andon System ROI Calculator

What These Numbers Mean

How Savings Are Calculated

See real results in your plant

Related Resources