The numbers already filled in are examples, not Optomech data. Replace each one with your plant’s figures. Results update as you type.
A. Manual inspection today
B. Your line
C. Cost of defects that slip through today
D. Your assumptions after automating
E. System to compare against
Your estimate
- Annual manual inspection cost
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- Inspectors employed
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- Units per year
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- Manual cost per 1,000 units
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- Labour saving / year
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- Quality cost avoided / year
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- Estimated annual saving
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- System price used
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- Simple payback
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How we calculate
Letters match the inputs above. Every figure is computed from your inputs; the only Optomech data used is the published starting-from price band for the system you choose.
| Result | Formula |
|---|---|
| Inspectors employed | N × S |
| Annual manual inspection cost (M) | N × S × C × 12 |
| Units inspected per year (U) | V × 60 × h × S × D |
| Manual inspection cost per 1,000 units | M ÷ U × 1,000 |
| Labour saving (L) | (N − R) × S × C × 12 (R is capped at N) |
| Current cost of escaped defects (Q) | I × K |
| Quality cost avoided (A) | Q × P ÷ 100 |
| Estimated annual saving (T) | L + A |
| Simple payback, months | System price ÷ T × 12 (shown for the low and high end of the band; no payback if T is ₹0) |
What this estimate leaves out
- GST, freight, installation extras, AMC, financing and the time value of money.
- False rejects, line stoppages and labour cost increases over time.
- Any detection rate for an Optomech system. How much of your incident cost a system avoids depends on your product, defects and line; that is why it is your assumption (P). Ask us for a trial on your samples.
- The line is assumed to run for every shift you enter (units per year uses S shifts × h hours).
Example inputs
These are the starting values in the calculator. They are illustrative only and are not Optomech or industry benchmarks.
| Input | Example value |
|---|---|
| Inspectors per shift (N) | 4 |
| Shifts per day (S) | 2 |
| Monthly cost per inspector, ₹ (C) | 25,000 |
| Line speed, units per minute (V) | 120 |
| Hours per shift (h) | 8 |
| Working days per year (D) | 300 |
| Complaint / recall incidents per year (I) | 4 |
| Average cost per incident, ₹ (K) | 200,000 |
| Inspectors per shift still needed (R) | 1 |
| Share of incident cost you expect to avoid, % (P) | 50 |
| System | CIS Online cap inspection (₹6–15 lakh) |
Price bands used
Optomech starting-from price bands for a base configuration, ex-works (Hyderabad), GST extra, as published on our product pages and the vision price guide. Your configured price depends on scope.
| System | Band |
|---|---|
| BIS-XL bottle inspection | ₹35–50 lakh |
| BIS STD+ bottle inspection | ₹25–40 lakh |
| BIS-EDB eye-dropper bottle inspection | ₹25–40 lakh |
| BIS-SC sealing surface inspection | ₹6–12 lakh |
| CIS Online cap inspection | ₹6–15 lakh |
| CIS Custom cap inspection | ₹6–15 lakh |
| CIS-XL cap inspection | ₹25–45 lakh |
| Spiral desiccant closure inspection | ₹6–20 lakh |
| IML Label Inspector | ₹20–30 lakh |
| LIS 2S label inspection (two sides) | ₹10–20 lakh |
| LIS 360° label inspection | ₹20–40 lakh |
| OCR / OCV print inspection | ₹6–10 lakh |
| ISIVS induction seal inspection (single station) | ₹20–40 lakh |
| ISIVS advanced station (high-speed / multi-camera) | ₹35–55 lakh |
| Fill level inspection | ₹6–9 lakh |
| FOSIS flip-off seal inspection | ₹25–40 lakh |
| CANIS canister inspection | ₹25–40 lakh |
| PBIS polybag inspection | ₹15–25 lakh |
| FDIS filter drier inspection | ₹15–20 lakh |