INTERACTIVE TOOL
Inspection ROI Calculator
Estimate the return on investment for automated inspection systems based on your production parameters. Adjust the inputs below to see projected savings, payback period, and 5-year ROI.
Your Production Parameters
500,000 boards/year
10K5M
$75
$5$500
2.5%
0.1%10%
4.0%
0.1%15%
2 lines
112
Note: This calculator uses an 85% defect reduction and a 75% rework reduction as its assumptions. Actual results vary based on your specific products, processes, and current quality levels. Contact us for a detailed analysis tailored to your operation.
Projected Results
7.5 months
Estimated Payback
699%
5-Year ROI
Investment Summary
| Equipment (2 lines) | $400,000 |
| Installation & integration | $30,000 |
| Training | $10,000 |
| Total Investment | $440,000 |
Estimated Annual Savings
| Scrap cost savings | $318,750 |
| Rework cost savings | $420,000 |
| Total gross savings | $738,750 |
| Less: annual service costs | -$36,000 |
| Net Annual Savings | $702,750 |
Projected Quality Improvement
Defect Rate
2.5% 0.4%
Rework Rate
4.0% 1.0%
5-Year Financial Summary
| Total 5-year net savings | $3,513,750 |
| Total investment | $440,000 |
| Net 5-year benefit | $3,073,750 |
| 5-Year ROI | 699% |
Calculation Assumptions
System Costs
- Average $200K per line (SPI + AOI)
- $15K installation per line
- $10K training (one-time)
- $18K annual service per line
Quality Improvements
- 85% defect reduction
- 75% rework rate reduction
- 40% of defects result in scrap
- $28 average rework cost per board
Not Included (Conservative)
- Warranty cost savings
- Manual inspection labor savings
- Increased throughput value
- Customer retention value
Your Results May Vary
- Actual costs depend on specific system configuration
- Improvement rates vary by process maturity
- High-value boards see faster payback
- Contact us for a detailed, customized analysis
Want a Detailed Analysis Tailored to Your Operation?
Our applications team can build a comprehensive ROI model using your actual production data, including factors this calculator does not cover such as labor savings, warranty reductions, and capacity improvements.