KOMPASS AI Product Inspection ROI Calculator

See what poor quality costs your line today and what automated visual inspection with KOMPASS could change. Get annual savings, payback, NPV and return on outlay in minutes, plus a free PDF to share with your team.

Build your line, step by step

Work through five short steps to compare your line today with KOMPASS. Results update live on the right. Every figure starts as a representative sample, so replace each one with your own numbers.

Production parameters

Units inspected per day

Working days per year

Operating hours per day

hrs

Used only for the capacity check — how those units are spread across your shifts.

Your part's inspection complexity

Simple, fast partse.g., biscuits / FMCG Moderate complexitye.g., pharma packaging Complex / multi-anglee.g., automotive, engine bores

This sets KOMPASS's rated inspection speed for the capacity check — you're describing your own part, not guessing our spec.

Current inspection system

Select your current inspection setup.

Fully manual inspectionNo automated system — every unit is inspected by a human operator. Existing system — all products reviewedYou have an automated inspection system, but its detection accuracy isn't high enough to rely on alone — every product still gets a manual look regardless of what it flags. Existing system — only rejects reviewedA rule-based system pre-screens; a person only reviews what it flags as a reject.

Current review time per unit (seconds)

Time your team currently spends per unit, looking at every single one.

Expected reduction in manual review time

40%

An adjustable planning assumption, not a confirmed Jidoka figure — set it to how much less manual review time you expect to need. KOMPASS is a 100% inspection system, but a person is still usually kept for oversight and exception handling, so we don't default to a full 100% cut.

Current quality metrics

Current defect rate

Share of units genuinely defective, however they're caught or missed — a property of your line, not of your inspection system. Should be ≥ the escape rate below.

Current defect escape rate

Share of defective units that currently reach the customer undetected.

Current false reject rate

Share of good units your current process wrongly rejects.

Labor & cost parameters

Inspector hourly rate

Rework cost per unit

Cost per defect reaching the customer

Cost per false reject

Defect cost: returns, credits, sorting at the customer, recall exposure, per unit. False reject: material and handling cost of a good unit wrongly rejected. Rework: cost to fix a genuinely defective unit caught before it ships.

Automation investment

System cost (per station)

Implementation (one-time)

Annual maintenance (per station)

These are placeholders, not Jidoka pricing — replace them with your own quoted figures. Implementation is assumed largely one-time regardless of station count.

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Advanced assumptions

Discount rate (WACC)

Model horizon

Your business case

Annual savings

—

per year, with KOMPASS

Payback period

— mo

months to break even

Typical KOMPASS payback (6–12 mo)Your scenario

Jidoka's KOMPASS deployments typically see payback in 6–12 months — shown alongside your own scenario, not in place of it.

3-year NPV

—

discounted at %

Return on outlay

—

over the full horizon

Labor hours saved

—

review hours / year

Want these numbers checked against your actual line?

This is a planning estimate, not a quotation or a guarantee of results. Detection accuracy (>99%) and false-reject reduction (40%) are Jidoka-confirmed figures applied for you; everything else is an editable assumption.

Where the annual savings comes from

Fewer defects reaching customers
Fewer false rejects
Manual review labor
Rework (can go either way)
Total

Catching more real defects is the point of better detection — but it means more units sent for rework, not fewer. That line can be negative, and that's expected: it's usually far outweighed by the drop in escape cost.

Annual cost comparison

Current annual cost
With KOMPASS
Annual savings

Escaped-defect cost + false-reject cost + manual review labor cost, combined — the same three streams as annual savings, shown as totals.

Current system analysis

Current process

Units reviewed/year
Time per unit
Total hours/year
Labor cost

With KOMPASS

Review time reduction
Remaining hours
Labor cost

"Review time reduction" is your adjustable assumption from step 2, not a confirmed Jidoka figure — unlike the detection numbers elsewhere.

Current system vs. with KOMPASS

	Current	With KOMPASS
Defect escape rate
False reject rate
Manual review hours / yr (your assumption)

KOMPASS performance used in this model

Industry-leading accuracy, with minimal false rejections.

>99%Detection accuracy (confirmed)

40%False-reject reduction (confirmed)

Same every timeNo fatigue or shift drift (structural)

Quality & efficiency improvements

Detection accuracy	>99%
False-reject reduction	40%
Escape rate reduction (your scenario)
Labor cost savings (your scenario)
Review hours saved / yr (your scenario)

How to read this

Investment summary

Initial investment

Stations required
System cost
Implementation
Total investment

3-year financial impact

Total savings
Net benefit
Return on outlay

System, implementation and maintenance figures are placeholders, not Jidoka pricing, unless you've entered your own quotes.

— / yr · — mo payback

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