Operations Cost Calculator Live

Are you losing money in your operations without knowing it? The Operations Cost Calculator helps business owners, managers, and operations leaders quantify exactly how much operational waste is costing them using the proven Lean Six Sigma 8 Wastes framework. Most businesses know something is wrong. Margins are shrinking. Productivity is inconsistent. Costs keep climbing. But without a number attached to the problem, it's impossible to justify change. WHAT IT DOES Enter your observations across the 8 categories of operational waste. (Defects, Overproduction, Waiting, Non-Utilized Talent, Transportation, Inventory, Motion, and Extra-Processing) and calculate your annual hidden cost impact. Every entry shows you the math, not just the result. THE 8 WASTES — DOWNTIME Defects — Rework, errors, and quality failures Overproduction — Delivering more than the customer needs Waiting — Idle time for staff and equipment Non-Utilized Talent — Skill mismatch and under-tasking Transportation — Unnecessary movement of materials, data, or people Inventory — Annual carrying cost of excess stock or backlog Motion — Unnecessary movement and searching Extra-Processing — Doing more than the customer paid for Each waste category includes a contextual insight, including Theory of Constraints for inventory, Critical to Quality, Delivery, and Cost frameworks for extra-processing, and flow principles for waiting and transportation. KEY FEATURES Instant dollar calculation across all 8 waste categories Direct Impact vs. Capacity Value breakdown Recovery Potential slider — see what recovering 10%, 20%, or 50% means in real dollars Named observations — label each entry for your report Ranked calculations page — wastes sorted by annual dollar impact with full formula transparency Email your full analysis — complete with the math — directly from the app Multiple currency support — USD, EUR, GBP, JPY, MXN, INR, CNY Works offline — no account required, no login, no subscription Data persists on your device between sessions WHO IT'S FOR Business owners and executives Operations and general managers Continuous improvement and Lean Six Sigma practitioners Supply chain and logistics leaders Healthcare, hospitality, and service industry operators Retail and distribution managers Operations consultants and business analysts MBA students and business school faculty Anyone responsible for efficiency, cost reduction, or process improvement THE METHODOLOGY The Operations Cost Calculator is built on DPS-Lean, a methodology developed by Jerry DeFranco, a 20-year defense and aerospace veteran, Lean Six Sigma Master Black Belt, PMP, and doctoral candidate. DPS-Lean integrates Theory of Constraints (identify the constraint), Lean Six Sigma (exploit and improve it), and Agile (execute improvements rapidly). It has been applied across manufacturing, defense, healthcare, and service industries. READY TO RECOVER YOUR REVENUE? Once you've quantified your waste, the next step is fixing it. DPS-Lean offers workshops, consulting, training, and Lean Six Sigma certification programs designed to turn your hidden revenue number into real bottom-line recovery. Visit dps-lean.com to learn more or book a free discovery call.