Operational Cost Simulation

This simulation estimates the annual costs associated with operating the batch process, including operator hours, major and minor deviations, and batch discards.

Baseline Costs:

Operator: ~$120k/yr (1k batches * 3hrs * $40/hr)
Supervisor Summary: ~$60k/yr (1k batches * 1hr * $60/hr)
Minor Dev. Handling: ~$5k/yr (50 * 2.5hrs * $40/hr)
Major Dev. RCA: ~$60k/yr (25 * 30hrs * $80/hr)
Major Dev. Overhead (lab tests/samples) ~$50k/yr (25 * $2k)
Batch Discards (Major Dev): ~$375k/yr (25 * $15k)

Simulation Inputs (data and assumptions)

Operator Hours per Batch Report (Hours)

Low

Most Likely

High

Manual Summary Hours per Batch (Hours / Batch)

Low

Most Likely

High

Batches per Year

Low

Most Likely

High

Batch Discard Cost ($ / Discarded Batch)

Low

Most Likely

High

Operator Hourly Rate ($ / hr)

Low

Most Likely

High

Expert Hourly Rate ($ / hr)

Low

Most Likely

High

Supervisor Hourly Rate ($ / hr)

Low

Most Likely

High

Major Deviations per Year

Low

Most Likely

High

Expert Hours per Major Deviation (Hours)

Low

Most Likely

High

Major Deviation Overhead Cost ($ / Major Deviation)

Low

Most Likely

High

Minor Deviations per Year

Low

Most Likely

High

Extra Operator Hours per Minor Deviation (Hours)

Low

Most Likely

High

Number of Iterations

Simulation Results

Adjust inputs on the left and click "Run Simulation"

to see the results of the simulation.