Free tool
Factory Layout ROI Calculator
Calculate the payback time for reorganizing your factory layout to shorten material travel distance.
Current situation
Planned new layout
Result: factory layout reorganization payback
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You enter the current and planned movement distance per cycle, the number of cycles per day, the labour hourly rate, the travel speed, the investment and the number of working days. Distance saved = current − new; daily time saved = distance ÷ speed × cycles ÷ 60 (in hours); annual saving = time × hourly rate × working days; payback (months) = investment ÷ annual saving × 12.
Example: 180 m → 70 m, speed 60 m/min, 40 cycles a day, EUR 18/h, an investment of EUR 15,000 and 230 working days give 110 m saved, 1.22 h a day, EUR 5,060 a year and a payback of 35.6 months.
Frequently asked questions
What does payback period mean?
The time in which the investment is earned back through savings. Up to 12 months is fast, up to 36 reasonable and beyond that long.
What does the calculation not include?
Downtime during the re-layout, effects on safety and quality, and output growth. These should be assessed separately.
What happens if the saving is zero?
If the new distance is not shorter, the tool shows “—” as the payback period and a warning.
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Methodology and limitations
Methodology based on standard industry calculations and Maintest’s practical industrial experience. This tool provides a planning estimate and does not replace project-specific engineering assessment. This tool is a screening and planning aid developed by Maintest. Results are indicative and depend entirely on the figures and answers you enter. They are not an engineering calculation, a safety assessment or a substitute for the manufacturer’s instructions, applicable standards or professional judgement. Weights, benchmarks and default values are Maintest planning assumptions and can be adjusted to your situation. Do not use this tool as the only basis for safety-critical decisions such as lifting, electrical work or lockout procedures.
Tool version 1.0 · Updated October 2026
Related project: Factory relocation from Tallinn to Saue
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