4 CUSTOMER CASES

How Manufacturing Companies Can Save Money with PLEET Stop

From small subcontractors to large packaging manufacturers—here are four concrete examples of how reduced downtime impacts the bottom line.

CASE 1

Small metalworking company—5 employees

163,800 DKK

savings per year

Payback:

7 months

CASE 2

Medium-sized metalworking company – 19 employees

226,512 DKK

savings per year

Payback:

3 months

CASE 3

Large metalworking company—50+ employees

573,120 DKK

savings per year

Payback:

3 months

CASE 4

Packaging Production – 40+ employees

468,000 DKK

savings per year

Payback:

4 months

Case 1

Small metalworking company

Machining of metal and/or plastic workpieces

5

5 employees

A smaller, more efficient organization

7

7x STAR Long-Turners

Requires I/O modules for data collection

2

2 3-axis CNC machining centers

Part of the overall fleet of machinery

9

9 machines in total

Basis for the calculation

The Challenge

15 hours per month

On average, each machine was idle for 15 hours per month due to downtime or changeover times that lasted longer than expected.

The Solution: PLEET Stop

-20%

PLEET Stop reduces downtime by 20% —equivalent to 3 hours and 45 minutes more production time per machine each month.

1,620 metric tons

Current annual downtime (all machines)

819,000 DKK

Current annual downtime cost

324 t

Reduced downtime per year with PLEET

163,800 DKK

Annual savings on downtime costs

COSTS FOR PLEET

TOTAL Year 1 (operating expenses + startup costs)
150,000 DKK

TOTAL for Year 2 and beyond (operations only)
135,000 DKK

NET VALUE

Net value, Year 1
13,800 DKK

Net worth in Year 2 and beyond
28,800 DKK

Payback Period
7 months

7 months

The investment in PLEET Stop pays for itself in just 7 months—after that, the savings are pure profit, year after year.

Case 2

Medium-sized metalworking company

Machining of metal and/or plastic workpieces · two-shift schedule

19

19 employees

Several machines are operating on a two-shift schedule

3

3x Long-turners

Requires I/O modules for data collection

4

4 x 3-axis CNC machining centers

Part of the overall fleet of machinery

1

1 x 4-axis CNC machining center

Part of the overall fleet of machinery

2

2 5-axis CNC machining centers

Part of the overall fleet of machinery

10

10 machines in total

Basis for the calculation

The Challenge

12 hours per month

On average, each machine was idle for 12 hours per month due to downtime or changeover times that lasted longer than expected.

The Solution: PLEET Stop

-22%

PLEET Stop reduces downtime by 22% —equivalent to 3 hours and 45 minutes more production time per machine each month.

1,440 metric tons

Current annual downtime (all machines)

1,029,000 DKK

Current annual downtime cost

317 t

Reduced downtime per year with PLEET

226,512 DKK

Annual savings on downtime costs

COSTS FOR PLEET

TOTAL Year 1 (operating expenses + startup costs)
165,000 DKK

TOTAL for Year 2 and beyond (operations only)
150,000 DKK

NET WORTH

Net value, Year 1
61,512 DKK

Net worth in Year 2 and beyond
76,512 DKK

Payback Period
3 months

3 months

The investment in PLEET Stop pays for itself in just 3 months—after that, the savings are pure profit, year after year.

Case 3

Large metalworking company

Machining of metal and/or plastic workpieces · 3-shift schedule

50+

50+ employees

Several machines are operating on a three-shift schedule

2

2 x Long-turners

Requires I/O modules for data collection

7

7 x 3-axis CNC machining centers

Part of the overall fleet of machinery

8

8 x 4-axis CNC machining centers

Part of the overall fleet of machinery

7

7 x 5-axis CNC machining centers

Part of the overall fleet of machinery

24

24 machines in total

Basis for the calculation

The Challenge

12 hours per month

On average, each machine was idle for 12 hours per month due to downtime or changeover times that lasted longer than expected.

The Solution: PLEET Stop

-20%

PLEET Stop reduces downtime by 20% —equivalent to more than 2½ hours more production time per machine each month.

3,456 t

Current annual downtime (all machines)

2,865,000 DKK

Current annual downtime cost

691 t

Reduced downtime per year with PLEET

573,120 DKK

Annual savings on downtime costs

COSTS FOR PLEET

TOTAL Year 1 (operating + startup costs)
366,600 DKK

TOTAL for Year 2 and beyond (operations only)
303,600 DKK

NET WORTH

Net value, Year 1
206,520 DKK

Net worth in Year 2 and beyond
269,520 DKK

Payback Period
3 months

3 months

The investment in PLEET Stop pays for itself in just 3 months—after that, the savings are pure profit, year after year.

Case 4

Food Packaging Production

Vacuum forming and injection molding · 3-shift schedule

40+

40+ employees

Several machines are operating on a three-shift schedule

15

15 vacuum forming machines

8

8 injection molding machines

23

23 machines in total

The Challenge

25 hours per month

On average, each machine was idle for 25 hours per month due to downtime or changeover times that lasted longer than expected.

The Solution: PLEET Stop

-25%

PLEET Stop reduces downtime by 25% —equivalent to more than 2½ hours more production time per machine each month.

6,900 metric tons

Current annual downtime (all machines)

3,120,000 DKK

Current annual downtime cost

1,035 t

Reduced downtime per year with PLEET

468,000 DKK

Annual savings on downtime costs

COSTS FOR PLEET

TOTAL Year 1 (operating expenses + startup costs)
345,600 DKK

TOTAL for Year 2 and beyond (operations only)
294,600 DKK

NET WORTH

Net value, Year 1
122,400 DKK

Net worth in Year 2 and beyond
173,400 DKK

Payback Period
4 months

4 months

The investment in PLEET Stop pays for itself in just 4 months—after that, the savings are pure profit, year after year.

Customer Review:

“We’ve seen a significant improvement in our production since we installed PLEET. The time spent on production downtime has been reduced to such an extent that it’s making a difference on the bottom line.” “

– Claus Kvist, Plant Manager, ST PLAST A/S

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