Free tools
Tools for production and maintenance managers
26 free calculators, checklists and generators — from production downtime cost to factory expansion readiness.
Maintenance & Reliability
Maintenance maturity test
35 questions, 7 categories — assess your plant’s maintenance maturity and get personalized recommendations.
- You enter: Answers to multiple-choice questions
- You get: Score, radar chart and recommendations
- Time: about 5–10 min
Equipment criticality calculator
Assess equipment criticality across 6 weighted factors and get a concrete maintenance strategy recommendation.
- You enter: Your own figures
- You get: Calculated result and scenarios
- Time: about 2–3 min
Spare parts calculator
Enter your spare part data and get a clear recommendation — stock it, or order on demand.
- You enter: Your own figures
- You get: Calculated result and scenarios
- Time: about 2–3 min
MTBF/MTTR/OEE calculator
Calculate your equipment’s reliability (MTBF, MTTR) and Overall Equipment Effectiveness (OEE).
- You enter: Your own figures
- You get: Calculated result and scenarios
- Time: about 2–3 min
Maintenance plan generator
Generate a recommended maintenance plan tailored to your equipment type and criticality.
- You enter: Basic details
- You get: A printable document
- Time: about 3–5 min
Maintenance backlog planner
Prioritize your maintenance backlog and see how many weeks it will take your crew to clear it.
- You enter: Your own figures
- You get: Calculated result and scenarios
- Time: about 2–3 min
PLC/HMI backup check
Check how ready your PLC, HMI/SCADA and drive backups are for a fast recovery after a failure.
- You enter: Answers to multiple-choice questions
- You get: Score, radar chart and recommendations
- Time: about 5–10 min
Production & Downtime
Downtime cost calculator
Calculate the real cost of production downtime — per event, per year, and potential savings.
- You enter: Your own figures
- You get: Calculated result and scenarios
- Time: about 2–3 min
Shutdown planner
Plan a maintenance shutdown’s task sequence, parallel tracks and total cost.
- You enter: Your own figures
- You get: Calculated result and scenarios
- Time: about 2–3 min
Bottleneck calculator
Find your production line’s bottleneck station and its cost in lost throughput.
- You enter: Your own figures
- You get: Calculated result and scenarios
- Time: about 2–3 min
Takt time and capacity calculator
Calculate your line’s required takt time and compare it against your actual cycle time and capacity.
- You enter: Your own figures
- You get: Calculated result and scenarios
- Time: about 2–3 min
Changeover loss calculator
Calculate the annual value of reducing your changeover time toward a SMED target.
- You enter: Your own figures
- You get: Calculated result and scenarios
- Time: about 2–3 min
Factory Relocation & Layout
Relocation downtime planner
Estimate the expected downtime and total cost of relocating your equipment or factory.
- You enter: Your own figures
- You get: Calculated result and scenarios
- Time: about 2–3 min
Factory relocation risk score
Score the risk level of your factory or equipment relocation across 5 key areas.
- You enter: Answers to multiple-choice questions
- You get: Score, radar chart and recommendations
- Time: about 5–10 min
Layout ROI calculator
Calculate the payback time for reorganizing your factory layout to shorten material travel distance.
- You enter: Your own figures
- You get: Calculated result and scenarios
- Time: about 2–3 min
Factory expansion readiness check
Score your plant’s readiness for expansion across space, utilities, people, supply chain and finance.
- You enter: Answers to multiple-choice questions
- You get: Score, radar chart and recommendations
- Time: about 5–10 min
Installation & Commissioning
Installation readiness check
30 questions, 6 categories — assess whether the installation site is truly ready for new equipment.
- You enter: Answers to multiple-choice questions
- You get: Score, radar chart and recommendations
- Time: about 5–10 min
Utilities readiness check
Check whether your site’s electrical, compressed air, water and ventilation systems are ready for new equipment.
- You enter: Answers to multiple-choice questions
- You get: Score, radar chart and recommendations
- Time: about 5–10 min
FAT/SAT generator
Generate a ready-made FAT/SAT checklist for your equipment’s factory test and on-site test.
- You enter: Basic details
- You get: A printable document
- Time: about 3–5 min
Cost & ROI
Repair, retrofit or replace
Compare the lifecycle cost (NPV/TCO) of three scenarios — repair, retrofit, or new equipment.
- You enter: Your own figures
- You get: Calculated result and scenarios
- Time: about 2–3 min
Machine TCO calculator
Calculate your equipment’s total cost of ownership (TCO) over its lifetime, discounted to present value.
- You enter: Your own figures
- You get: Calculated result and scenarios
- Time: about 2–3 min
Maintenance budget calculator
Calculate a recommended annual maintenance budget based on your asset replacement value.
- You enter: Your own figures
- You get: Calculated result and scenarios
- Time: about 2–3 min
Asset Management
Asset lifecycle tracker
See where your equipment sits in its lifecycle and how much to reserve annually for replacement.
- You enter: Your own figures
- You get: Calculated result and scenarios
- Time: about 2–3 min
Used machine pre-purchase inspection
Score a used machine’s condition across 5 categories before you buy it.
- You enter: Answers to multiple-choice questions
- You get: Score, radar chart and recommendations
- Time: about 5–10 min
Risk & Incident Response
First 60 minutes after a major failure
Generate a first-60-minutes action plan for responding to a major equipment breakdown.
- You enter: Basic details
- You get: A printable document
- Time: about 3–5 min
5 Whys root cause analysis
Run a structured 5 Whys analysis to find the root cause of an equipment failure.
- You enter: Basic details
- You get: A printable document
- Time: about 3–5 min