Helicoil / Pin Installation ROI Simulator

Scenario Control

editable

Currency Import JSON

Tip: for justification meeting, run Conservative / Expected / Aggressive and show payback sensitivity against final-stage workpiece loss.

Calculation Guardrail

This simulator treats rework, scrap, and external escape as separate cost buckets. Use conservative rates to avoid double-counting the same defect event. For a final-stage damaged workpiece, do not use raw aluminium price only: include raw material, all previous machining/grinding/milling/process hours, engineering, procurement, logistics, inspection, tooling wear, carbide tips/cutters, overhead, and replacement/admin cost.

1. Production & Finance

Annual production volume / parts per year Working days per year Discount rate % for NPV Analysis horizon / years Target payback / years Other annual quantified benefit

2. Final-stage Workpiece Loss Build-up

Use this when scratch, damage, helicoil damage, pin damage, or non-weldable defect is found at final stage and the whole workpiece has to be scrapped. The simulator can use either a direct manual value or a detailed accumulated-cost estimate.

Use detailed accumulated-cost estimate

2A. Direct value / raw material

Manual final-stage loss per scrapped part Length / m Width / m Thickness / m Aluminium density kg/m³ Material cost per kg Scrap recovery credit % Replacement admin / logistics cost

2B. Pre-final process cost already spent

Procurement/admin hours Procurement/admin rate per hour Engineering/CAM/programming hours Engineering rate per hour Incoming inspection / QA cost Internal logistics / transport / packing Setup / fixturing amortized per part Outsourced/subcontract process cost CNC / rough machining hours CNC machine rate per hour Milling / finishing hours Milling rate per hour Grinding hours Grinding rate per hour Drilling/tapping/thread prep hours Drilling/tapping rate per hour CMM/final inspection hours Inspection rate per hour Surface treatment / coating / cleaning Factory overhead / WIP burden %

2C. Tooling and consumables already consumed

Carbide tips / inserts quantity Carbide tip / insert cost each Cutter wear cost allocated per part Drill / tap / reamer consumables Grinding wheel / stone / abrasive Coolant / deburr / cleaning consumables Gross accumulated workpiece value Net final-stage loss used in ROI

3. Current Manual Process

Manual helicoil/pin labour min per part Operators for installation Labour rate per hour Current manual QC min per part QC operators QC labour rate per hour Current total cycle min per part Current rework rate % Average rework cost per event Current final-stage scrap rate % Current customer escape rate % Average external failure cost per escape

4. Proposed System

New tending / handling labour min per part New operators New QC audit/review min per audited part Manual QC audit ratio % New total cycle min per part New rework rate % New final-stage scrap rate % New customer escape rate % Capacity contribution per hour Annual maintenance / service Annual cloud/software/support Annual calibration/spares/consumables

5. Project Investment

Machine / AI system project price Integration / installation Fixtures / tooling / safety guarding Training / validation / FAT-SAT Grant / subsidy / internal offset Residual value at end of horizon

ROI Output

ready

Total investment-

Gross annual benefit-

Annual OPEX-

Net annual benefit-

Payback period-

Year 1 ROI-

NPV-

IRR-

Final-stage Workpiece Loss Build-up

Cost element	Value	Formula / note

Annual Benefit Breakdown

Bucket	Annual value	Comment

Cash Flow

Year	Cash flow	Discounted	Cumulative

Workpiece Loss Sensitivity

Final-stage loss	Net annual benefit	Payback

Helicoil / Pin Installation ROI Calculator