Configure the facility and keep the ROI in view.

Beta release

This ROI calculator is currently in beta and may make mistakes. Please verify important numbers before relying on them.

Choose your industry

Rakes received per day

/ day

Wagons per rake

wagons

Material value — Coking Coal / Iron Ore

/ T

Number of wagon tipplers

units

Yard lines (tracks)

lines

Your designation

Tailors the live business case to your role.

1

Arrival & Advance Intimation

₹5,28,000/yr

Your rake is en-route. Your yard doesn't know yet.

Without FOIS integration, your RMHS team knows a rake is arriving only when it's at the gate. Yard lines aren't cleared, the loco isn't positioned, the crew isn't ready. The clock starts — and you're already behind. Every minute of unpreparedness is demurrage-eligible time accumulating.

Advance notice your team typically gets

Yard preparation time needed

min
Annual arrival idle cost (loco @ ₹800/hr)₹5,28,000
2

Entry & Weighment

₹10,56,000/yr

Gross weight captured. Wagon number? Written on a clipboard.

As the rake passes the motion weighbridge, weights are captured sequentially. But the system doesn't know which wagon is which. Someone writes it down, manually. That clipboard is now your chain of custody for the full material value of the rake.

Wagon number recording method

Time to associate wagon numbers after weighment

min
Industry median is 20–30 min. You're running 30 min above average — adding ₹5,28,000 in excess idle per year.
Annual data delay idle cost₹10,56,000

Include weight reconciliation gap

Industry avg for manual ops: 0.1–0.3% of total tonnage. Conservative. Defaults off.

3

Structural Profiling

₹31,68,000/yr

Does your team inspect every wagon? Or wave it through?

A bulged wagon entering your yard grid is not a maintenance issue, it's a potential blockage of your entire single-track system. A sick wagon that goes undetected gets tipped and damages your tippler. Manual visual inspection catches perhaps 60% of defects at best.

Current inspection method at entry

Sick / damaged wagons per 100 received

%

Avg blockage when compromised wagon enters yard

hrs
Below Steel median of 2.1%. Your team is catching most defects at entry.
Annual structural incident idle cost₹31,68,000
4

Yard Movement & Rail Switching

₹3,87,600/yr

How many minutes does your team spend walking to a point switch?

On a single-track grid, every wagon movement requires a point change. A yard supervisor walks to the switch, changes the rail, signals clearance, walks back. The loco waits. Multiply that across every rake and every switch and it is hours of pure loco idle time daily.

Rail point switch operation method

Average time per point switch

min

Point switches per rake cycle

switches
Annual rail switching idle cost₹3,30,000

Include yard congestion incidents

Full grid halts due to undetected congestion (avg 45 min to resolve).

Congestion incidents per month

/mo
5

Level Crossing

₹21,00,000/yr

Every crossing needs a guard. Unless it doesn't.

For every rake movement crossing a level crossing, a guard must be physically present. Every crossing event is a guard, a delay, and a statutory liability, repeated across 330 operating days a year.

Level crossings at your plant

crossings

Average time per crossing event

min

Guards deployed per crossing (per shift)

guards
Guard manpower cost / yr₹14,40,000
Crossing delay idle cost / yr₹6,60,000
6

Tippler Operations

₹2,90,07,000/yr

The most dangerous 90 seconds in your plant. Repeated hundreds of times daily.

The tippling cycle looks automated. But manual pin removal, the wrong wagon at the wrong tippler, undetected residual material, and a human standing in the side charger zone each represent either a safety incident or a throughput cost nobody is measuring.

Average tippler idle time per shift

min

Re-tips needed per rake (residual material)

wagons
Tippler idle cost / yr₹4,95,000
Residual material loss / yr (0.8T avg per re-tip)₹2,85,12,000
⚠️

Safety note: Side charger zones account for the highest frequency of proximity incidents in Indian RMHS operations. Rake Guard detects any human presence and halts the tippler in under 2 seconds, before the tipping cycle initiates.

7

TAT Tracking & MIS

₹39,000/yr

If you can't measure it, you can't fix it. And right now, you can't measure it.

Your RMHS generates 50+ distinct events per rake. Without automated TAT tracking, none are timestamped or correlated. Every loss in the earlier stages is invisible on your MIS. Invisible losses never get fixed.

Current rake TAT tracking method

Hours per week spent on manual MIS preparation

hrs/wk
≈ 8% of a full-time analyst's annual capacity on MIS alone
Annual MIS analyst time cost (₹250/hr)₹39,000
Make it visible: Every loss in the earlier stages has been accumulating since your plant started operations. TAT tracking is what makes it visible, measurable, and permanently fixable.