Interactive Tool

Your shift-start device scramble has a price tag.

See exactly how much manual device assignment costs your manufacturing operation every year — in dollars, hours, and IT burden.

1
Step 1Configure Your Facility

Your Operation

Select your industry, then adjust the sliders to match your facility.

Industry
$46.30/hrFully-loaded labour cost
$901Avg. device replacement
10%Annual device loss rate
3.5%Labour cost inflation
Workers per shift 100
102,000
ForwardPass smart locker solutions are typically deployed in facilities with 50+ shared devices. For smaller operations, contact us to discuss options.
Shifts per day
Shared devices 80
102,000
Minutes lost at shift start 13 min
5 min30 min
Avg. device replacement cost $901
$300$3,000
2
Step 2Your Cost Estimate
Estimated Annual Cost of Device Assignment Waste
$---,---
per year, based on your inputs
Move a slider to see your estimate
That's $0.00 per worker, per day • $0 every month this continues
$0
Labour Waste
$0
Device Loss
Since you opened this page: $0.00

How should we frame this for your team?

Select your focus below to get a role-specific breakdown you can share with stakeholders — plus a personalised PDF report.

Ops Directors • Procurement
$0
Annual cost of doing nothing
That's $0.00 per worker per day — before overtime, production delays, or compliance exposure. At your fully-loaded labour cost of $46.30/hr, every minute your people spend hunting for a device is money walking off the floor.
CI / Lean • Maintenance
0 hrs
Productive hours lost per year
Equivalent to 0 full-time employees per year standing around waiting for devices. If your Lean program is focused on eliminating waste, this is 0 hours of muda hiding in every shift change.
IT Managers • CIOs
0 hrs
IT hours consumed by device replacement per year
That's 0 devices lost annually at your facility, each requiring ~4 hours of IT time for procurement, imaging, provisioning, and decommission. This doesn't include troubleshooting, support tickets, or the Friday afternoon calls when someone's scanner won't turn on.
3
Step 3Unlock Full Assessment

3-Year Cost Projection

If nothing changes, here's what the next three years look like.

YearLabour WasteDevice LossTotal
Year 1
Year 2
Year 3
3-Year Total

How You Compare

MetricYour FacilityIndustry AvgVariance

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  • 3-year cost projection with compounding
  • How your operation compares to General Manufacturing benchmarks
  • Executive-ready PDF — formatted for forwarding to leadership
  • Prioritised next steps based on your inputs
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This estimate does not include supervisor oversight time, overtime costs, production delays, or compliance risk exposure. Actual total cost of manual device management is likely higher than shown.

How We Calculated This

Every default value in this calculator is sourced from published, independent research. Here's exactly where the numbers come from.

13-Minute Shift-Start Benchmark

Imprivata / Vanson Bourne, 2025 — Independent survey. Frontline workers lose an average of 13 minutes per shift to shared device assignment. 87% of teams encounter access issues at shift start. Study conducted in healthcare shared-device environments; causes of delay are common across frontline settings.

$901 Average Replacement Cost

Imprivata / Ponemon Institute, 2024 — Survey of 1,795 respondents. Manufacturing had the highest average device replacement cost at $901. 16% of enterprise mobile devices lost annually.

Fully-Loaded Labour Cost

Bureau of Labor Statistics — ECEC Q2 2025. Total manufacturing compensation: $46.30/hr. Sub-verticals: Food & Bev $36.50/hr, Aerospace $61.50/hr, Automotive $55.00/hr. Benefits loading factor: 49.6%.

Device Loss Rate

Imprivata / Ponemon, 2024. 16% annual loss across all enterprise mobile devices. Calculator uses conservative estimates: Food & Bev 12%, Aerospace 5%, Automotive 10%, General 10%.

Limitations & Assumptions

  • The 13-minute benchmark was measured in healthcare shared-device environments. Causes of delay are common across frontline environments.
  • Device loss rates vary by industry, facility security practices, and device type. Defaults are conservative vs. the 16% Ponemon finding.
  • 3-year projections assume current headcount and shift patterns with annual labour cost inflation only.
  • IT support hours are estimated at 4 hours per device replaced (procurement, imaging, provisioning, decommission). Actual burden depends on team structure and processes.

This tool provides estimates based on your inputs and published industry research. Results are not guaranteed and will vary based on your specific operational conditions. All default values are adjustable.

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