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
Wagons per rake
Material value — Coking Coal / Iron Ore
Number of wagon tipplers
Yard lines (tracks)
Your designation
Tailors the live business case to your role.
Arrival & Advance Intimation
₹5,28,000/yrYour 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
Entry & Weighment
₹10,56,000/yrGross 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
Include weight reconciliation gap
Industry avg for manual ops: 0.1–0.3% of total tonnage. Conservative. Defaults off.
Structural Profiling
₹31,68,000/yrDoes 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
Yard Movement & Rail Switching
₹3,87,600/yrHow 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
Point switches per rake cycle
Include yard congestion incidents
Full grid halts due to undetected congestion (avg 45 min to resolve).
Congestion incidents per month
Level Crossing
₹21,00,000/yrEvery 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
Average time per crossing event
Guards deployed per crossing (per shift)
Tippler Operations
₹2,90,07,000/yrThe 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
Re-tips needed per rake (residual material)
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.
TAT Tracking & MIS
₹39,000/yrIf 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