OEE & Factory Performance worked example

Factory Dashboard Savings at 58% realization rate: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop realization rate to 58%, then walk the calculation through step by step. Estimate annual savings from dashboard-driven loss reduction.

The inputs for this scenario

  • Operators using dashboards: 100 operators (held at the documented default)
  • Hours saved per operator: 45 hr (held at the documented default)
  • Realization rate: 58 % (the input this scenario stresses; the baseline uses 80)
  • Annual platform license cost: 250 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Weighted cost = quantity × rate × capture factor + fixed adjustment.
  • Total factory dashboard savings cost works out to 2,860 $ at these inputs, and this is the headline figure for the scenario.
  • Factory dashboard savings cost per unit works out to 28.6 $ / piece at these inputs.
  • Variable factory dashboard savings cost works out to 2,610 $ at these inputs.
  • Fixed factory dashboard savings adder works out to 250 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where realization rate sits at 80% and the headline result is 3,850 $, this scenario comes in 25.71% below the baseline at 2,860 $.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to realization rate, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. The output is only as credible as the capture factor you choose; an optimistic factor inflates the case, and the model can't tell you whether the assumed savings rate is actually achievable on your floor.

Results at a glance

  • Total factory dashboard savings cost: 2,860 $ (headline result)
  • Factory dashboard savings cost per unit: 28.6 $ / piece
  • Variable factory dashboard savings cost: 2,610 $
  • Fixed factory dashboard savings adder: 250 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Factory Dashboard Savings calculator, set realization rate to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.