Factory layout ROI calculator
Put numbers on your next layout change: what stopping the line and planning the move costs today, and what rehearsing it in a digital twin first could save.
Projected savings per layout change
$78,000
Based on your numbers and the two reduction assumptions on the sliders. Drag either slider to see how the outcome shifts.
- Downtime cost$240,000 → $168,000
- Planning cost$12,000 → $6,000
Savings over 5 years
$390,000Cumulative, at 1 layout change a year.
Cumulative savings by year: year 1, $78,000; year 2, $156,000; year 3, $234,000; year 4, $312,000; year 5, $390,000.
Why layout changes are expensive
Moving machines in a running factory costs more than the movers' invoice. Three costs dominate the bill.
Lost production
Every hour the line stands still is output you never ship. For most plants this is the largest cost of a layout change, and it grows every time the restart doesn't go to plan.
Planning and engineering
Measuring the floor, drawing layout options, and aligning production, logistics, and maintenance can take months of engineering hours before anything moves.
Trial and error
On paper, every layout works. Clearance, material flow, and vehicle route problems tend to show up after the machines have physically moved, and every correction means stopping the line again.
How a digital twin changes the math
moicon doesn't move the machines. It lets you rehearse the whole change in a 3D replica of your factory, so problems surface digitally instead of on the floor.
Verify fit and flow before anything moves
Drag and drop machinery inside a 3D replica of your factory to check placement, clearances, and material flow, down to the routes your AGVs will drive.
Simulate the new layout's throughput
Model the line with sources, processors, and buffers, then run the simulation to find the bottlenecks a new layout would create, before it exists.
Compare complete layouts as snapshots
Save each candidate layout as a snapshot of the same project and switch between them until the numbers and the flow both work. The running factory stays untouched.
See how others did it
Hapro plans production line moves in a digital twin of their running factory, and Ovun designed the layout of an entire new facility virtually before construction began.