ROI Calculator
Apex Automotive Stamping LLC · 3 active CI projects · Auto-populated from DMAIC data
Project Inputs — Apex CI Portfolio
Monthly Scrap Loss (Line 2)
$38,400 / month
Ford PPM Warranty Risk (annual)
$72,000 est.
Downtime Cost (9.4 hrs/wk)
$18,800 / month
Changeover Productivity Loss
$8,200 / month
SOP Rework from Outdated Docs
$4,100 / month
PlantPilot AI Investment
$15,000 / month
PLANTPILOT AI · ROI ANALYSIS
Apex's current CI losses total $841,200 annualized. PlantPilot AI's 3 active projects target $412,000 in verified savings — a 5,380% ROI at $15K/mo investment. Conservative model assumes 70% capture rate on scrap and downtime savings. Full realization requires completing DMAIC Improve phase and sustaining SOP compliance above 90%.
Annual Savings Identified
$412K
verified from active projects
$38.4K scrap + $72K warranty + $225.6K downtime + $75.6K other
Return on Investment
5,380%
annualized at $15K/mo
$412K savings / $180K investment = 2.29× net positive
Savings Breakdown by Project
Line 2 Scrap Reduction (DMAIC — Analyze phase)
+$384,000
Line 1 SMED Changeover (DMAIC — Control phase)
+$98,400
Ford PPM Corrective — Warranty risk reduction
+$72,000
SOP Compliance Improvement (14 overdue → current)
+$49,200
PlantPilot AI Monthly Fee (12 months)
−$180,000
Net Annual Value
+$423,600
Document Generator
AI-generated documents from your real facility data — board presentations, 8D reports, SOPs, and more
Executive Business Case
Ford 8D Report
Kaizen Charter
Control Plan (IATF)
PFMEA Update
$412K
Annual Savings Identified
5,380%
Projected ROI
60–90
Days to Full ROI
3
Active DMAIC Projects
Current State — Apex Automotive Stamping LLC
Line 2 scrap rate vs target3.1% vs 1.5% — $38,400/mo loss
Ford PPM (Wayne Assembly)142 vs 50 — warranty escalation active
PM compliance71% — 8 overdue PMs (SAP gap)
Line 1 changeover time47 min avg — SMED target 28 min
PlantPilot AI Active Projects & Outcomes
Line 2 Die Scrap DMAIC (Analyze)Root cause confirmed — die insert replacement approved
Ford PPM DMAIC (Define)Containment active — 8D submitted May 28
Line 1 SMED (Control)Pilot avg 28.75 min — target achieved
Investment Summary
PlantPilot AI monthly subscription$15,000 / month
Annual investment$180,000
Identified annual savings$412,000
Net annual value+$232,000 (Year 1) · +$412,000 (Year 2+)