MDT Software Return On Investment Project Justification Tool

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R.O.I. Summary

Overall ROI for a Change Management System    
Shortest R.O.I. 0.00 Months
Average R.O.I. 0.00 Months
Longest R.O.I. 0.00 Months
     

Costs Summary

Click on the heading to see the details.

Cost Data for a Change Management System Current
Worst Case
Current
Best Case
Current
Average
AutoSave
Total New Change Management System Cost       0.00
Annual cost for Versioning 9,660.00 2,100.00 5,880.00 770.00
Annual cost of Backups 14,700.00 4,637.50 9,668.75 0.00
Annual cost of Lost Code 258,044.18 68,477.74 163,260.96 4,593.02
Annual Total Cost 282,404.18 75,215.24 178,809.71 5,363.02
Your Annual Total Savings with AutoSave 277,041.16 69,852.22 173,446.69  
         

U.S. F.D.A. Form 483 & Warning Letter Costs

Cost for a single F.D.A. Event
Corrective Action 150,000.00
Consultants 175,000.00
Quality System Improvement Initiatives 500,000.00
Fines 0.00
Interruptions in Production 0.00
   
Total Cost to Respond 825,000.00

Data Input

Update figures in this table and press update to compute (or recompute) Return on Investment.

About your Plant Operations
Is your plant subject to U.S. F.D.A. Form 483 & Warning Letters  
What is...    
the average number of code changes per day? per day
the average number of days per week of operations? per week
the average number of weeks per year of operations? per year
the number of devices in you plant that require routine backups? (PLC's, HMI's, Drives, etc) devices
the frequency of backups for each device per month? per month
the average man hour cost including overhead?  
the estimated downtime cost per hour?  
the number of days between software/hardware failure that require a reload? (Lost Code Event) days
Time estimates for modifying a program Worst Case
(Minutes)
Best Case
(Minutes)
How much time does it take...    
your automation staff to find and identify the correct program related to a PLC or HMI?
to launch the editor software related to a PLC or HMI?
to change or enter parameters into a program?
to save the changes?
to archive the old revision of a program on a network server?
to copy a new version to a network server?
to make notes in the change log or on a server?
Time estimates for creating a backup program Worst Case
(Minutes)
Best Case
(Minutes)
How much time does it take...    
to prepare and execute a plan to conduct backups?
to physically go to each device?
to connect to a device?
to create backup?
to copy the backup to a network server?
to make notes in a change log or on a server?
Downtime due to a Lost Code Incident Worst Case
(Minutes)
Best Case
(Minutes)
How much time does it take...    
to locate and retrieve the correct backup for the program?
to re-create changes made in after the last backup?
Total Cost to Implement a Change Management System (CMS)
Software Cost (quote from MDT)  
Implementation Cost (quote from MDT)  
Hardware/Software Infrastructure Cost (from your I.T. Department)  
Annual Support Contract (quote from MDT)  

Input for U.S. F.D.A. Form 483 & Warning Letter Costs

Corrective Action    
Cost to Assemble Team  
Cost per Person per year
Number of Team Members persons
Length of Engagement months
Consultants    
Cost per Person per year
Number of Team Members persons
Length of Engagement months
Quality System Improvement Initiatives    
Cost to Assemble Team  
Cost per Person per year
Number of Team Members persons
Length of Engagement months
Employee Attrition -- Cost to replace employee  
Implementation Cost  
Fines    
Fines total
Interruptions in Production    
Plant Closing  
Shift Production to new Facility  
Production Cost -- Outsourcing  

Details for Versioning & Backup

Version Creation Process Current
Worst Case
(Minutes)
Current
Best Case
(Minutes)
Current
Average
(Minutes)
AutoSave
(Minutes)
Find and identify the correct program 30 3 16.50 2.00
Launch the Editor 2 1 1.50 1.50
Change or enter communications parameters 4 1 2.50 0.00
Go Online and Make Changes        
Save Changes 1 1 1.00 1.00
Archive Old Copy on Network Server 15.00 5.00 10.00 0.00
Copy new version to Network Server 7.00 2.00 4.50 0.00
Make notes in change log or on server 10.00 2.00 6.00 1.00
Total minutes used per code change 69.00 15.00 42.00 5.50
Manual Backup Process Current
Worst Case
(Minutes)
Current
Best Case
(Minutes)
Current
Average
(Minutes)
AutoSave
(Minutes)
Prepare Plan to Conduct Backups 5.00 2.00 3.50 0.00
Go to each Device 20.00 5.00 12.50 0.00
Connect to Device 2.00 0.25 1.12 0.00
Create Backup 5.00 2.00 3.50 0.00
Copy on Network Server 5.00 2.00 3.50 0.00
Make Notes in Change Log or on Server 5.00 2.00 3.50 0.00
Total minutes used per Backup 42.00 13.25 27.63 0.00
AutoSave System Cost Information
Software Cost 0      
Implementation Cost 0      
Hardware/Software Infrastructure Cost 0      
Initial Annual Support Contract 0      
Total New System Cost 0.00      
Your Plant Information
Average number of code changes per day 0.50      
Average days per week of operation 5.0      
Average weeks per year of operation 48      
Average code changes per year 120.00      
Number of Devices to Backup 25      
Backup Frequency per Month 1.00      
Backups per Year 300.00      
Versioning Costs Current
Worst Case
Current
Best Case
Current
Average
AutoSave
Annual man hours spent on Versioning 138.00 30.00 84.00 11.00
Annual cost for Versioning 9,660.00 2,100.00 5,880.00 770.00
Your Annual Versioning Manpower Savings with AutoSave 8,890.00 1,330.00 5,110.00  
         
Backup Costs Current
Worst Case
Current
Best Case
Current
Average
AutoSave
Annual man hours spent on Backups 210.00 66.25 138.13 0.00
Annual cost of Backups 14,700.00 4,637.50 9,668.75 0.00
Your Annual Backup Manpower Savings with AutoSave 14,700.00 4,637.50 9,668.75  
         
         

Details for Lost Code

This calculation does not take into account time to notice nor diagnose the event as those are not changed with or without AutoSave

Program Restore Process Current
Worst Case
(Minutes)
Current
Best Case
(Minutes)
Current
Average
(Minutes)
AutoSave
(Minutes)
Locate and retreve the last backup 10.00 30.00 20.00 2.00
Launch the Editor 2 1 1.50 1.50
Change or enter communications parameters 4 1 2.50 0.00
Recreate changes made after the last backup 60.00 240.00 150.00 0
Save Changes 1 1 1.00 1.00
Archive Old Copy on Network Server 15.00 5.00 10.00 0.00
Copy new version to Network Server 7.00 2.00 4.50 0.00
Make notes in change log or on server 10.00 2.00 6.00 1.00
Total Minutes Lost Code Event 309.00 82.00 195.50 5.50
AutoSave System Cost Information
Software Cost 0      
Implementation Cost 0      
Hardware/Software Infrastructure Cost 0      
Initial Annual Support Contract 0      
Total New System Cost 0.00      
Lost Code Data Current
Worst Case
Current
Best Case
Current
Average
AutoSave
Hours lost per Lost Code Event 5.15 1.37 3.26 0.09
Hours lost per year 5.15 1.37 3.26 0.09
Cost per Lost Code Event 257,860.50 68,429.00 163,144.75 4,589.75
Annual cost of Lost Code 258,044.18 68,477.74 163,260.96 4,593.02
Your Annual Savings with AutoSave 253,454.43 63,887.99 158,671.21  
Your Per Event Savings with AutoSave 253,270.75 63,839.25 158,555.00  
         
Events to pay for AutoSave 0.00 0.00 0.00