Industry 4.0 Gap Calculator

A visual sales tool for estimating the annual cost of lost capacity caused by OEE underperformance, hidden downtime, scheduling inefficiency, and weak operational visibility.

Estimated annual performance gap: $0 —

Plant Assumptions

Adjust the operating assumptions to expose the financial cost of lost performance.

Number of Machines

Average Hourly Cost ($)

Hours / Machine / Week

Working Weeks / Year

Current OEE65%

Target Achievable OEE80%

Hidden Operational Loss10%

🏭

Weekly Capacity

0 hrs

◎

OEE Lost Hours / Week

0 hrs

⏱

Hidden Lost Hours / Week

0 hrs

Total Annual Gap

Annual Loss Breakdown

Use the visual breakdown to shift the conversation from software cost to recoverable capacity.

OEE Gap

Hidden Loss

Total Gap

Calculation Summary

A simple financial bridge from operational loss to executive urgency.

Current Productive Hours / Week

0 hrs

Achievable Productive Hours / Week

0 hrs

OEE Gap Annual Loss

Hidden Loss Annual Impact

Sales Talk Track

Use this during executive conversations.

“Based on your current assumptions, the plant may be leaving $0 on the floor each year.”

“The next step is to validate where that loss comes from: downtime, scheduling, poor visibility, integration gaps, or process breakdowns.”

This positions the Industry 4.0 Readiness Assessment as the logical next move.

TSRB Path Forward
Production Intelligence captures the truth. I4DM connects the systems. MERIT 2.0 governs the work to closure.