Savings Estimator
What's variation costing you?
Five questions about your line. We'll show you how much continuous thickness monitoring is worth, in scrap saved, material 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
Plate Height
Average plate dimension
mm
Plate Width
Average plate dimension
mm
Strip Quantity
Strips running in parallel
strips
Strip Width
mm
Strip Thickness
Target thickness (the nominal)
mm
Line Speed
m/min
Operating Days Per Year
days
Daily Uptime
Hours the line runs each day
hrs
What are your costs?
This helps us calculate how much money is at stake.
Lead Oxide Cost
What you pay per kg
$
/kg
Scrap Cost Per Plate
Total cost when a plate gets red-tagged
$
Density of Lead
g/cm³
Remelt Loss ?Out-of-spec strip is clean lead that goes back into your melt pot. This is the dross and oxidation yield you lose each time you remelt it. Around 2% is typical. Set it to 0 to ignore remelt entirely (no scrap bucket), matching the original sheet.
% yield lost to dross when remelting out-of-spec strip
%
How much does your thickness vary?
This determines how much material gets wasted and how many plates get scrapped. If you're unsure, use the suggested values below each field.
Current Std Dev (Manual)
How much plates vary from target today
mm
Expected Std Dev (Mate Gauge)
We typically cut variation by 50%
mm
Red Tag Limit
Plates outside this tolerance get scrapped
±mm
Safety Margin
?Many lines deliberately run thicker than target as a buffer, so no plate drifts under the lower spec. That shifts your whole manual distribution toward the thick side. With continuous monitoring you can trust target and remove that buffer, saving material on every plate. Set this to the over-thickness you run today.
Optional. % you deliberately run thicker than target (typical: about 2%)
%
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, and every micron of shift = direct material savings on every plate. 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
Year 1 ROI
—
Payback
—
5-Year Net Gain
—
Where the savings come from
▪ Savings from variation reduction ?When thickness varies a lot, operators over-run every plate with extra material to stay safe. We calculate the average over-run using your standard deviation, multiply by plate area, density, and cost per unit weight.
—
▪ Savings from scrap reduction ?Material outside your red tag limit gets scrapped or remelted. We use the normal distribution (bell curve) to calculate what percentage falls beyond that limit.
—
▪ Supplementary Savings ?Softer savings from automated monitoring: less operator training time, easier OE compliance, fewer downstream jams, and better brand value. Click to adjust each value. ▾
—
Reduced training time
$
OE compliance demonstration
$
Brand / quality value
$
Less downstream scrap & jams
$
▪ Savings from Nominal Shift ?Material saved by lowering target thickness toward the lower spec, made possible by tighter variation control. Adjust the slider under the bell curve to see how aggressive you want to be.
—
▪ Savings from removing safety margin ?If you currently run deliberately thicker than target as a buffer, continuous monitoring lets you trust target and drop that buffer. This is the material saved on every plate by removing the over-thickness. Adjust the safety margin slider under the bell curve.
—
How The Bell Curve Works
Every plate lands somewhere on this curve. The tighter the curve, the more consistent your output, and the less money you waste.
Manual control (incl. safety margin)
With Mate Gauge
With Nominal Shift
Scrap zone
Safety Margin
0.00%
Nominal Shift
0.00%
What your current variation is costing you today
Wasted Lead Oxide
—
Scrapped Plates
—
The Executive Summary
Your Line
Line Speed
plt/min
Strip Quantity
qty
Strip Width
mm
Strip Thickness
mm
Line Speed
m/min
Operating Days
days
Daily Uptime
hrs
Plate Height
mm
Plate Width
mm
Costs
Lead Oxide Cost
$/kg
Scrap Cost / Plate
$
Density of Lead
g/cm³
Remelt Loss
%
Process Variation
Std Dev (Manual)
mm
Std Dev (Mate Gauge)
mm
Red Tag Limit
±mm
Safety Margin
%
Savings Estimator
What's variation costing you?
Five questions about your line. We'll show you how much continuous thickness monitoring is worth, in scrap saved, material 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
Plate Height
Average plate dimension
mm
Plate Width
Average plate dimension
mm
Strip Quantity
Strips running in parallel
strips
Strip Width
mm
Strip Thickness
Target thickness (the nominal)
mm
Line Speed
m/min
Operating Days Per Year
days
Daily Uptime
Hours the line runs each day
hrs
What are your costs?
This helps us calculate how much money is at stake.
Lead Oxide Cost
What you pay per kg
$
/kg
Scrap Cost Per Plate
Total cost when a plate gets red-tagged
$
Density of Lead
g/cm³
Remelt Loss ?Out-of-spec strip is clean lead that goes back into your melt pot. This is the dross and oxidation yield you lose each time you remelt it. Around 2% is typical. Set it to 0 to ignore remelt entirely (no scrap bucket), matching the original sheet.
% yield lost to dross when remelting out-of-spec strip
%
How much does your thickness vary?
This determines how much material gets wasted and how many plates get scrapped. If you're unsure, use the suggested values below each field.
Current Std Dev (Manual)
How much plates vary from target today
mm
Expected Std Dev (Mate Gauge)
We typically cut variation by 50%
mm
Red Tag Limit
Plates outside this tolerance get scrapped
±mm
Safety Margin
?Many lines deliberately run thicker than target as a buffer, so no plate drifts under the lower spec. That shifts your whole manual distribution toward the thick side. With continuous monitoring you can trust target and remove that buffer, saving material on every plate. Set this to the over-thickness you run today.
Optional. % you deliberately run thicker than target (typical: about 2%)
%
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, and every micron of shift = direct material savings on every plate. 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
Year 1 ROI
—
Payback
—
5-Year Net Gain
—
Where the savings come from
▪ Savings from variation reduction ?When thickness varies a lot, operators over-run every plate with extra material to stay safe. We calculate the average over-run using your standard deviation, multiply by plate area, density, and cost per unit weight.
—
▪ Savings from scrap reduction ?Material outside your red tag limit gets scrapped or remelted. We use the normal distribution (bell curve) to calculate what percentage falls beyond that limit.
—
▪ Supplementary Savings ?Softer savings from automated monitoring: less operator training time, easier OE compliance, fewer downstream jams, and better brand value. Click to adjust each value. ▾
—
Reduced training time
$
OE compliance demonstration
$
Brand / quality value
$
Less downstream scrap & jams
$
▪ Savings from Nominal Shift ?Material saved by lowering target thickness toward the lower spec, made possible by tighter variation control. Adjust the slider under the bell curve to see how aggressive you want to be.
—
▪ Savings from removing safety margin ?If you currently run deliberately thicker than target as a buffer, continuous monitoring lets you trust target and drop that buffer. This is the material saved on every plate by removing the over-thickness. Adjust the safety margin slider under the bell curve.
—
How The Bell Curve Works
Every plate lands somewhere on this curve. The tighter the curve, the more consistent your output, and the less money you waste.
Manual control (incl. safety margin)
With Mate Gauge
With Nominal Shift
Scrap zone
Safety Margin
0.00%
Nominal Shift
0.00%
What your current variation is costing you today
Wasted Lead Oxide
—
Scrapped Plates
—
The Executive Summary
Your Line
Line Speed
plt/min
Strip Quantity
qty
Strip Width
mm
Strip Thickness
mm
Line Speed
m/min
Operating Days
days
Daily Uptime
hrs
Plate Height
mm
Plate Width
mm
Costs
Lead Oxide Cost
$/kg
Scrap Cost / Plate
$
Density of Lead
g/cm³
Remelt Loss
%
Process Variation
Std Dev (Manual)
mm
Std Dev (Mate Gauge)
mm
Red Tag Limit
±mm
Safety Margin
%