PLM, BOM & Digital Thread worked example

Part Reuse Savings at 36% reuse opportunities captured: a worked example

This worked example runs the part reuse savings numbers for a tougher week than the baseline: 36% reuse opportunities captured instead of the typical 50%. Estimates the savings from reusing approved parts instead of introducing new part numbers in fresh designs.

The inputs for this scenario

  • New designs reusing existing parts: 240 designs (held at the documented default)
  • Avoided new-part introduction cost: 850 $/design (held at the documented default)
  • Reuse opportunities captured: 36 % (the input this scenario stresses; the baseline uses 50)
  • Reuse program annual cost: 10,000 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Net savings = reusing designs x avoided cost x capture rate + program cost.
  • Total part reuse savings cost works out to 83,440 $ at these inputs, and this is the headline figure for the scenario.
  • Part reuse savings cost per unit works out to 348 $ / piece at these inputs.
  • Variable part reuse savings cost works out to 73,440 $ at these inputs.
  • Fixed part reuse savings adder works out to 10,000 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where reuse opportunities captured sits at 50% and the headline result is 112,000 $, this scenario comes in 25.5% below the baseline at 83,440 $.
  • Use it when justifying a part standardization initiative, setting reuse targets, or reporting the value your reuse program returned last year. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Total part reuse savings cost: 83,440 $ (headline result)
  • Part reuse savings cost per unit: 348 $ / piece
  • Variable part reuse savings cost: 73,440 $
  • Fixed part reuse savings adder: 10,000 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Part Reuse Savings calculator, set reuse opportunities captured to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.