PLM, BOM & Digital Thread worked example

Duplicate Part Cost at 81% truly redundant share: a worked example

This scenario runs the duplicate part cost calculation on the strong side: 81% truly redundant share, with every other input held at its documented default. Use it to justify a part-rationalization initiative by quantifying the money tied up in duplicate items.

The inputs for this scenario

  • Duplicate part numbers in PLM: 180 parts (unchanged)
  • Lifecycle carrying cost per part: 950 $/part/yr (unchanged)
  • Truly redundant share: 81 % (raised for this scenario; the documented default is 70)
  • Cleansing project setup cost: 6,000 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total exposure = duplicate parts x carrying cost x redundant share + setup cost) to the inputs above produces each figure below.
  • At this operating point the engine returns 144,510 $ for total duplicate part cost, the number this scenario is built around.
  • At this operating point the engine returns 803 $ / piece for duplicate part cost per unit.
  • At this operating point the engine returns 138,510 $ for variable duplicate part cost.
  • At this operating point the engine returns 6,000 $ for fixed duplicate part cost adder.

How this compares with the baseline

  • Against the tool's baseline example, where truly redundant share sits at 70% and the headline result is 125,700 $, this scenario comes in 14.96% above the baseline at 144,510 $.
  • Use it when scoping a PLM data-quality initiative, justifying part-number rationalization, or reporting the cost of poor master data to leadership. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Total duplicate part cost: 144,510 $ (headline result)
  • Duplicate part cost per unit: 803 $ / piece
  • Variable duplicate part cost: 138,510 $
  • Fixed duplicate part cost adder: 6,000 $

Run it with your numbers

  • Every input above is editable in the live Duplicate Part Cost calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.