Quick Answer:
Short Answer
Plants using legacy edge sensors typically spend $25,000-$75,000 per line annually on hidden costs including calibration labor, extended changeovers, and quality escapes.
The cost of continuing with legacy edge sensors includes:
Hidden Costs (Uncounted but Real)
- Calibration Labor: 2 hours monthly at $60/hour = $1,440/year per line
- Extended Changeovers: 2 extra minutes × 5 changes/day × 250 days at $1,000/hour = $41,700/year
- Troubleshooting Time: 4 hours/month diagnosing drift-related issues = $2,880/year
Risk Costs
- Quality Escapes: Undetected edge drift causing coating misregistration
- Equipment Damage: Missed edges leading to web wraps and bearing damage
Opportunity Costs
- Material Limitations: Cannot run clear films, mesh, or specialty materials
- Speed Constraints: Slow sensor response forces reduced line speeds
Typical Annual Cost of Inaction: $25,000 - $75,000 per line