Savings Estimator
What's variation costing you?
A few questions about your line. We'll show you how much continuous thickness monitoring is worth, in material saved, scrap reduced, and payback months. No email required.
1
Your Line
2
Costs
3
Variation
4
Results
Tell us about your line
We just need a few basics to calculate your annual production volume.
Line Speed
Plates per minute
plt/min
Number of Strips
Parallel strips / lanes on the line
strips
Line Speed
How fast the strip travels
m/min
Operating Days Per Year
days
Daily Uptime
Hours the line runs each day
hrs
Plate Height
Average plate dimension
mm
Plate Width
Average plate dimension
mm
Plate Thickness
Average finished plate thickness
mm
Strip Width
Width of each strip
mm
Strip Thickness
Target thickness
mm
What are your costs?
This helps us calculate how much money is at stake.
Lead Oxide Cost
What you pay per kg of paste
$
/kg
Scrap Cost Per Plate
Total cost when a plate gets red-tagged
$
Lead Cost
What you pay per kg of lead
$
/kg
Remelt Cost
Cost to reprocess off-spec strip, per kg (energy, labour, dross loss)
$
/kg
Paste Density
Density of your wet/cured paste — default is typical, edit if you know yours
g/cm³
Lead Density
Density of your lead alloy — default is typical, edit if you know yours
g/cm³
How much does your thickness vary?
This determines how much material gets wasted and how much falls out of spec. If you're unsure, use the suggested values below each field.
Current Std Dev (Manual)
How much you vary from target today
mm
Expected Std Dev (Mate Gauge)
We typically cut variation by 50%
mm
Red Tag Limit
Material outside this tolerance is out of spec
±mm
Safety Margin
?Many lines deliberately run thicker than target as a buffer against dipping under spec — for example +2% on every unit. That extra material is carried on every part, every day. With continuous monitoring you can trust the process and pull that buffer back toward target. Enter how much over target you run today.
Optional — % you deliberately run over target today
%
Nominal Shift
?How much of the newly-available thickness margin you choose to capture as material savings. Today you carry safety stock above the lower spec. With tighter variation, you can lower target thickness — every micron of shift = direct material savings. The slider on the results page caps at the physical maximum based on your inputs.
Optional — % reduction of target thickness (capped at physical max)
%
Your Mate Gauge system saves you
—
per year
Expected σ (Mate Gauge) is set higher than your current σ. The model treats them as equal, so variation and scrap savings are shown as zero until the expected value is lower.
Where the savings come from
▪ Savings from variation reduction ?When thickness varies a lot, you carry extra material on every unit to stay safe. We calculate the average excess using your standard deviation, multiplied by area, material density, and cost per unit weight.
—
▪ Savings from scrap reduction ?Material outside your red tag limit is out of spec. We use the normal distribution (bell curve) to calculate what fraction falls beyond that limit.
—
▪ Supplementary Savings ?Softer savings from automated monitoring: less operator training time, easier OE compliance, fewer downstream issues, and better brand value. Click to adjust each value. ▾
—
Reduced training time
$
OE compliance demonstration
$
Brand / quality value
$
Less downstream scrap & jams
$
▪ Savings from safety margin removal ?If you deliberately run thicker than target today as a buffer, that extra material is pure cost. Continuous monitoring lets you pull the average back toward target. This is the material saved by removing that buffer.
—
▪ Savings from Nominal Shift ?Material saved by lowering target thickness, made possible by tighter variation control. Adjust the slider under the bell curve to see how aggressive you want to be.
—
How The Bell Curve Works
Every unit lands somewhere on this curve. The tighter the curve, the more consistent your output — and the less money you waste.
Manual control
With Mate Gauge
Scrap zone
Nominal Shift
0.00%
Safety Margin
0.00%
What your current variation is costing you today
Wasted Lead Oxide
—
Scrapped Plates
—
The Executive Summary
Your Line
Line Speed
plt/min
Number of Strips
strips
Line Speed
m/min
Operating Days
days
Daily Uptime
hrs
Plate Height
mm
Plate Width
mm
Plate Thickness
mm
Strip Width
mm
Strip Thickness
mm
Costs
Lead Oxide Cost
$/kg
Scrap Cost / Plate
$
Lead Cost
$/kg
Remelt Cost
$/kg
Paste Density
g/cm³
Lead Density
g/cm³
Process Variation
Std Dev (Manual)
mm
Std Dev (Mate Gauge)
mm
Red Tag Limit
±mm
Savings Estimator
What's variation costing you?
A few questions about your line. We'll show you how much continuous thickness monitoring is worth, in material saved, scrap reduced, and payback months. No email required.
1
Your Line
2
Costs
3
Variation
4
Results
Tell us about your line
We just need a few basics to calculate your annual production volume.
Line Speed
Plates per minute
plt/min
Number of Strips
Parallel strips / lanes on the line
strips
Line Speed
How fast the strip travels
m/min
Operating Days Per Year
days
Daily Uptime
Hours the line runs each day
hrs
Plate Height
Average plate dimension
mm
Plate Width
Average plate dimension
mm
Plate Thickness
Average finished plate thickness
mm
Strip Width
Width of each strip
mm
Strip Thickness
Target thickness
mm
What are your costs?
This helps us calculate how much money is at stake.
Lead Oxide Cost
What you pay per kg of paste
$
/kg
Scrap Cost Per Plate
Total cost when a plate gets red-tagged
$
Lead Cost
What you pay per kg of lead
$
/kg
Remelt Cost
Cost to reprocess off-spec strip, per kg (energy, labour, dross loss)
$
/kg
Paste Density
Density of your wet/cured paste — default is typical, edit if you know yours
g/cm³
Lead Density
Density of your lead alloy — default is typical, edit if you know yours
g/cm³
How much does your thickness vary?
This determines how much material gets wasted and how much falls out of spec. If you're unsure, use the suggested values below each field.
Current Std Dev (Manual)
How much you vary from target today
mm
Expected Std Dev (Mate Gauge)
We typically cut variation by 50%
mm
Red Tag Limit
Material outside this tolerance is out of spec
±mm
Safety Margin
?Many lines deliberately run thicker than target as a buffer against dipping under spec — for example +2% on every unit. That extra material is carried on every part, every day. With continuous monitoring you can trust the process and pull that buffer back toward target. Enter how much over target you run today.
Optional — % you deliberately run over target today
%
Nominal Shift
?How much of the newly-available thickness margin you choose to capture as material savings. Today you carry safety stock above the lower spec. With tighter variation, you can lower target thickness — every micron of shift = direct material savings. The slider on the results page caps at the physical maximum based on your inputs.
Optional — % reduction of target thickness (capped at physical max)
%
Your Mate Gauge system saves you
—
per year
Expected σ (Mate Gauge) is set higher than your current σ. The model treats them as equal, so variation and scrap savings are shown as zero until the expected value is lower.
Where the savings come from
▪ Savings from variation reduction ?When thickness varies a lot, you carry extra material on every unit to stay safe. We calculate the average excess using your standard deviation, multiplied by area, material density, and cost per unit weight.
—
▪ Savings from scrap reduction ?Material outside your red tag limit is out of spec. We use the normal distribution (bell curve) to calculate what fraction falls beyond that limit.
—
▪ Supplementary Savings ?Softer savings from automated monitoring: less operator training time, easier OE compliance, fewer downstream issues, and better brand value. Click to adjust each value. ▾
—
Reduced training time
$
OE compliance demonstration
$
Brand / quality value
$
Less downstream scrap & jams
$
▪ Savings from safety margin removal ?If you deliberately run thicker than target today as a buffer, that extra material is pure cost. Continuous monitoring lets you pull the average back toward target. This is the material saved by removing that buffer.
—
▪ Savings from Nominal Shift ?Material saved by lowering target thickness, made possible by tighter variation control. Adjust the slider under the bell curve to see how aggressive you want to be.
—
How The Bell Curve Works
Every unit lands somewhere on this curve. The tighter the curve, the more consistent your output — and the less money you waste.
Manual control
With Mate Gauge
Scrap zone
Nominal Shift
0.00%
Safety Margin
0.00%
What your current variation is costing you today
Wasted Lead Oxide
—
Scrapped Plates
—
The Executive Summary
Your Line
Line Speed
plt/min
Number of Strips
strips
Line Speed
m/min
Operating Days
days
Daily Uptime
hrs
Plate Height
mm
Plate Width
mm
Plate Thickness
mm
Strip Width
mm
Strip Thickness
mm
Costs
Lead Oxide Cost
$/kg
Scrap Cost / Plate
$
Lead Cost
$/kg
Remelt Cost
$/kg
Paste Density
g/cm³
Lead Density
g/cm³
Process Variation
Std Dev (Manual)
mm
Std Dev (Mate Gauge)
mm
Red Tag Limit
±mm