## Estimate Your Machine Vision ROI
Use this calculator to estimate the potential return on investment from implementing automated visual inspection. Enter your current situation and system costs to see projected savings.
Current Inspection Costs
Full-time equivalents dedicated to inspection
Include benefits and overhead (~30% above base)
Percentage of defects missed by manual inspection
Customer returns, warranty, reputation damage
Total parts/products inspected annually
Percentage scrapped due to false rejects
Material and labor lost per false reject
Machine Vision System Costs
Camera, lighting, compute, integration
Integration, training, commissioning
Support contracts, updates, recalibration
Typical machine vision systems last 5-10 years
Expected Improvements
Typically 50-90% depending on application
AI typically catches 80-95% more than humans
Consistent AI reduces over-rejection
Disclaimer: This calculator provides estimates based on typical industry scenarios. Actual results vary significantly based on application complexity, product mix, existing processes, and implementation quality. Use these figures for initial planning only. We recommend conducting a detailed feasibility study with vendors for accurate projections.
How to Use This Calculator
Step 1: Enter Your Current Costs
Labor: How many people inspect products? Include their fully loaded cost (salary + benefits + overhead, typically 1.3x base salary).
Defect Escapes: What percentage of defects slip through to customers? Multiply by the cost per incident (returns, warranty claims, reputation damage).
False Rejects: Good products incorrectly rejected as defective waste material and labor.
Step 2: Enter System Costs
Get quotes from vendors for realistic figures. Budget options start around £5,000-10,000; enterprise systems can exceed £100,000.
Step 3: Estimate Improvements
Be conservative. Typical ranges:
- Labor reduction: 50-90% (rarely 100% - someone monitors the system)
- Defect escape reduction: 60-95% (AI catches more than humans)
- False reject reduction: 40-70% (consistent thresholds help)
Typical ROI by Industry
| Industry | Typical System Cost | Payback Period | Key Value Driver |
|---|---|---|---|
| Electronics/PCB | £20,000-80,000 | 6-18 months | Defect escape reduction |
| Automotive | £50,000-200,000 | 12-24 months | Compliance + labor |
| Food & Beverage | £15,000-50,000 | 6-12 months | Labor + consistency |
| Pharmaceutical | £30,000-100,000 | 12-18 months | Compliance + defects |
| General Manufacturing | £10,000-40,000 | 8-18 months | Labor savings |
Ready to Get Started?
- Explore your options: Keyence vs Cognex Comparison
- Learn the basics: What is Computer Vision?
- Try a DIY prototype: Raspberry Pi 3D Print Monitor
- Contact vendors: Request demos with your actual products
Related Resources
- Complete Guide to Weld Defect Detection
- YOLOv8 PCB Defect Detection Tutorial
- Best Datasets for Training Defect Detection Models
Need help with your machine vision project? Contact us for guidance.