Wire cutting machine output and ROI calculator

Estimate accepted wire leads per hour and per shift using your cut length, stripping operation and sample run. Compare the labor cost of making the same volume by hand and on a machine.

1. Production assumptions

Measured cycle time (s) Leads produced per cycle Scheduled shift (h) Time spent running (%) Accepted leads (%)

Time complete cycles at your target cut and strip lengths, including normal handling. Use two leads per cycle only after confirming that the machine runs both lines together at the cycle time you entered.

Estimate cycle time from feed and operations

Use this when the measured cycle time field is blank. Enter the actual average feed speed and add cutting, stripping and handling time that happens outside feeding.

Feed length per cycle (mm) Effective feed speed (m/min) Non-feeding operations (s/cycle)

2. Payback inputs (optional)

Use accepted output for both processes. Enter costs in the same currency and include payroll costs in your hourly rate.

Demand per shift (leads) Working shifts per month Manual output (accepted leads/person-hour) Loaded labor cost per person-hour Staffed hours per 100 machine hours Added operating cost per month Installed machine cost

Enter 100 for one operator per scheduled machine hour, or 25 for 15 staff minutes per scheduled machine hour. Include setup, loading and checks. The calculation scales staffing to the compared volume. If you pay staff for idle hours as well, include that pay in added operating cost per month. Enter 0 for any cost you have verified as zero.

Enter your production assumptions to calculate output.

How output and payback are calculated

Accepted leads per scheduled hour = 3,600 ÷ cycle seconds × leads per cycle × running fraction × acceptance fraction. Count all time lost to spool changes, stops and adjustments in the running fraction. Enter the accepted percentage separately to account for rejects.

Simple payback in months = installed machine cost ÷ monthly net savings. The comparison uses the lower of demand and machine capacity. Monthly savings subtract staffed machine labor and added operating costs from the manual labor cost for that same volume. Include freight, tooling and commissioning in your installed cost. Confirm your inputs against a representative run before committing to a purchase.

For a bench machine, review our automatic wire cutting and stripping machine WM-167. For longer wire, different insulation or multiple lines, compare the cut and strip machine range by application.

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