PLM, BOM & Digital Thread worked example

Duplicate Part Cost at 50% truly redundant share: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop truly redundant share to 50%, then walk the calculation through step by step. Estimates the annual carrying and rationalization cost of redundant part numbers sitting in the part master.

The inputs for this scenario

  • Duplicate part numbers in PLM: 180 parts (held at the documented default)
  • Lifecycle carrying cost per part: 950 $/part/yr (held at the documented default)
  • Truly redundant share: 50 % (the input this scenario stresses; the baseline uses 70)
  • Cleansing project setup cost: 6,000 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Total exposure = duplicate parts x carrying cost x redundant share + setup cost.
  • Total duplicate part cost works out to 91,500 $ at these inputs, and this is the headline figure for the scenario.
  • Duplicate part cost per unit works out to 508 $ / piece at these inputs.
  • Variable duplicate part cost works out to 85,500 $ at these inputs.
  • Fixed duplicate part cost adder works out to 6,000 $ at these inputs.

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 27.21% below the baseline at 91,500 $.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to truly redundant share, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. Carrying cost per part is an estimate that blends inventory, procurement, and admin overhead; it will vary widely by part class, so validate the rate against a sample before trusting the headline number.

Results at a glance

  • Total duplicate part cost: 91,500 $ (headline result)
  • Duplicate part cost per unit: 508 $ / piece
  • Variable duplicate part cost: 85,500 $
  • Fixed duplicate part cost adder: 6,000 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Duplicate Part Cost calculator, set truly redundant share to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.