Estimated ROI Calculatorper CNC machine

Compare return on investment across three analytics tiers. Physics Analytics uses existing controller data at zero hardware cost. Enhanced Analytics adds retrofit sensors. ML Analytics adds predictive intelligence for maximum savings.

Assumptions

Machines

Number of Machines10

Machine Cost$250K

Operating Hours / Month400 hrs

Costs

Operating Cost / Hour$85

Electricity Cost / kWh$0.12

Avg Power (kW)25 kW

Operator Cost / Hour$35

Tooling Cost / Month$2.5K

Baseline Performance

Downtime Hours / Month12 hrs

Scrap Rate3.5%

Part Value$150

Parts / Hour4

Sensors Required per Machine

Tri-axial Accelerometerx2

Vibration & chatter detection

$1,600

Temperature Probex2

Thermal drift compensation

$700

Acoustic Emission Sensor

Tool wear monitoring

$1,200

Coolant Flow Meter

Process optimization

$500

Current Clamp

Power analysis

$200

Total Sensor Investment$4.2K

Estimated Annual Savings per Machine

Each saving category shows which analytics tier unlocks it

Controller dataRetrofit data

Per-Machine Financial Summary

Est. Annual Savings$41.7K

Sensor Investment (one-time)-$4.2K

Est. Net Savings (Year 1)$37.5K

Est. ROI (Year 1)892%

Payback Period~1.2 months

Est. 5-Year Net Savings$204.2K

* All savings are estimates based on industry benchmarks. Actual results vary by machine condition, operation type, and implementation.