A research-backed estimate of where your operation may be leaking dollars — and how much of that is recoverable through better data systems.
We'll ask 7 quick questions about your plant. If you don't know an answer, "Don't know" is always an option and we'll use the industry average.
No account required. Numbers visible instantly.
Building your report...
Calculating your hidden cost exposure across five categories.
SDS works with companies of all sizes — this calculator doesn't.
This particular tool is built specifically for mid-tier manufacturers in the $50M–$500M revenue range with 50–500 employees. The research behind it — APQC benchmarking, ASQ Cost of Poor Quality data, Siemens downtime research — focuses on operations of this size.
Below $50M, operations typically don't have the back-office structure, MES systems, or shift patterns the research assumes. Above $500M, multi-plant complexity makes single-plant assumptions less reliable.
But your situation is still worth a conversation. Erik would be happy to spend 20 minutes on what's actually going on at your operation.
estimated recoverable per year through better data systems
Based on your stated operational characteristics. Adjust the toggles below to fine-tune based on what you know about your operation.
Total estimated hidden cost: $0
Data & Reporting
Manual Reporting Hours
High
$0
data-recoverable per year
Estimated total gap: $0
Where does your plant fall?
Doing better than peers → lower exposure
Manual Data Movement Between Systems
High
$0
data-recoverable per year
Estimated total gap: $0
Where does your plant fall?
Doing better than peers → lower exposure
Factory Floor Performance
Unplanned Downtime
High
$0
data-recoverable per year
Estimated total gap: $0
Where does your plant fall?
Doing better than peers → lower exposure
Scrap & Rework
High
$0
data-recoverable per year
Estimated total gap: $0
Where does your plant fall?
Doing better than peers → lower exposure
External Quality Failures
High
$0
data-recoverable per year
Estimated total gap: $0
Where does your plant fall?
Doing better than peers → lower exposure
Supply Chain & Inventory
Excess Inventory
High
$0
data-recoverable per year
Estimated total gap: $0
Where does your plant fall?
Doing better than peers → lower exposure
Expedited Freight
High
$0
data-recoverable per year
Estimated total gap: $0
Where does your plant fall?
Doing better than peers → lower exposure
Administrative Process Drag
AP / Invoice Automation
High
$0
data-recoverable per year
Estimated total gap: $0
Where does your plant fall?
Doing better than peers → lower exposure
Back-Office Process Labor
High
$0
data-recoverable per year
Estimated total gap: $0
Where does your plant fall?
Doing better than peers → lower exposure
Workforce Knowledge Risk
Workforce Knowledge Risk
Medium
$0
data-recoverable per year
Estimated total gap: $0
Where does your plant fall?
Doing better than peers → lower exposure
Total Data-Recoverable
$0
The portion of your hidden cost realistically addressable through better data systems, dashboards, integration, and analytics.
Total estimated hidden cost: $0
Cost Category
Total Gap
Data-Recoverable
Confidence
Your Position
Data & Reporting
Manual Reporting Hours
$0
$0
High
Manual Data Movement Between Systems
$0
$0
High
Factory Floor Performance
Unplanned Downtime
$0
$0
High
Scrap & Rework
$0
$0
High
External Quality Failures
$0
$0
High
Supply Chain & Inventory
Excess Inventory
$0
$0
High
Expedited Freight
$0
$0
High
Administrative Process Drag
AP / Invoice Automation
$0
$0
High
Back-Office Process Labor
$0
$0
High
Workforce Knowledge Risk
Workforce Knowledge Risk
$0
$0
Medium
Total Data-Recoverable
per year through better data systems
$0
$0
Adjust the toggles above to fine-tune
Based on your selections, your operation is already at or near top-quartile performance across all five categories.
That's worth confirming. Most plants we work with score Average or Bottom on at least one category — and many don't realize it until they instrument their operations. If you'd like to validate your top-quartile assessment with specific operational data, Erik can spend 20 minutes on your situation.
We'll send you a polished PDF version of this exact report — with your toggle settings — that you can share with your CFO, your team, or save for your next planning meeting.
Or send it to a colleague:
Assessment Tool
Manufacturing Data Maturity Scorecard
An 18-question assessment that tells you exactly where your operation stands across the five dimensions of the SDS Data Intelligence Framework — and where to focus first.
If you'd rather walk through your numbers with someone who builds data systems for mid-tier manufacturers, Erik can spend 20 minutes on your specific situation.
