Paper job card cost calculator

Work out what paper job cards and shift reports cost: filling them in on the shop floor, collecting and checking by the supervisor, retyping into the ERP and settling work orders. The example is filled with a typical process - change the figures to yours and see the working hours and annual cost.

Process steps

Add as many steps as your process has. The rate is the hourly cost of the person doing the step, including employer costs.

50%

It depends on the process: simple automation removes some steps, a custom system can take over most of them. Set your own assumption.

Where the time goes in manufacturing

  • Data reaches the system late

    Cards from a whole shift sit on a desk until the next day. Work order status and material usage in the ERP are out of date, and planning runs on yesterday's data.

  • Illegible and incomplete cards

    A missing work order number, an illegible quantity or the wrong machine means finding the operator and asking - often days later, when nobody remembers the details.

  • Entering the same data twice

    The operator writes the data on paper, then someone in the office types it into the ERP. Every retyping is a cost and another chance for an error.

How we calculate

  • Step cost: number of documents × minutes per document × hourly rate.
  • Corrections: documents needing corrections × extra minutes × the average rate of your steps.
  • Full-time staff: 160 working hours per month.
  • Saving: process cost × your assumption. We do not state up front how much can be removed - that depends on the process and only comes out of an analysis.

The calculator leaves out paper, printing, archiving and the cost of delays, such as missed early-payment discounts. The real cost of a process is usually higher.

Frequently asked questions

How many job cards should I enter?

The simplest way: number of operators × shifts per month, if everyone fills in one card per shift. If cards are per work order, enter the number of work orders per month.

What replaces paper job cards?

Usually a form on a tablet or a terminal at the workstation: the operator picks the work order from a list, enters quantities and the data goes straight to the ERP. The form checks for gaps, so there are fewer corrections.

Does it work without stable internet on the shop floor?

Yes, the app can be built to work offline and send data once the connection is back. This needs to be agreed at the start of the project because it affects the scope.

Is the data I enter sent anywhere?

No. The calculator runs in your browser and stores nothing on a server. The data reaches us only if you send the contact form yourself.

Related

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