1. The cost of labeling machine for bulk products comparable to the cost of the MES system implementation project. For simplicity, let both of them cost 7 million rubles.
2. Payback for marking lines enough easily considered, and is understandable to the one at whose expense the banquet:
- A team of 4 markers marks about 5 tons per shift;
- With an automated line, which is accompanied by 3 people, 15 tons are marked in the same time. Those. volume that can be performed by 3 teams of 4 people;
- Savings on personnel per month, taking into account 30% payroll taxes - 175,5 tr., per year ~ 2,1 million. Payback - 3,3 years. It is clear that the equipment has operating costs, but roughly so.
3. The payback of an MES system is rarely considered, so it is not clear to sponsors. If the choice is between investing 7 million in a topic with an understandable return and a topic with an incomprehensible return, the first one is chosen, the sponsors are not fools.
4. To calculate the payback of an MES system, you need to understand what effects should be expected from implementation.
Effects and average figures from our experience are published on our website: meat, cheeses, milk.
5. Take, for example, meat processing. A common problem with large volumes is underloads. The client ordered, they transferred it to production, and there they either mixed it up, or spoiled it, or did not have time for shipment. The MES-system begins to control the execution of orders even at the stage of creating a task for production. The system at any time shows which orders have not yet been shipped, where these products are, at what stage of readiness, whether they are in the task. This helps to reduce the percentage of underloads even where it was quite small.
- Let the plant use the MES system to reduce the number of underloads and increase order fulfillment, and hence shipment, by 1%.
- 1% to 15 tons (production from item 2) is 150 kg per day, or 22,5 tr, if the margin is about 150 rubles per kilogram of product.
- Per month - 657 thousand rubles, per year - 8,1 million.
- Payback less than a year. Only one of the effects.
6. Cheese example. Using the MES system, you can raise the average moisture content of cheese - this is one of the main ways to increase yields:
- To increase the yield of cheese by 0,5%, you need to increase the average moisture by about 0,3%. For most plants, this is a more than feasible task, especially if the technologist has a convenient tool for analysis and monitoring. I have provided statistics on the moisture content of cheese from several factories in this article.
- 0,5% of the output of 15 tons, which is 75 kg per day, or 22,5 tr, at a price of 300 rubles per kilogram of cheese. In contrast to the meat example, here we got an increase due to water, which we consider free, so we multiply by the price, not the margin.
- Then you can substitute the same numbers as in meat, we get the same payback.
7. If there is an option to invest 7 million with a payback of 3 years or with a payback of 1 year, the choice is also obvious, but in favor of the second.
8. To calculate the payback on the MES system, I took only one of the expected effects, on our website there are 4 of them for each industry, in fact there are more.
9. In general, when you budget for the next year, take a closer look at investments.
Understandable doesn't mean best.
Source: habr.com
