Routine Work Business Case Calculator

STEP 1: Calculate the cost of the problem

For this calculator, routine work includes tasks your employees perform regularly enough that they become familiar and largely automatic.

SAFETY

Estimate the annual cost of routine work safety events:

  • Recordable injuries
  • Lost-time injuries
  • First aid cases
  • Property damage
  • Environmental releases
  • Near misses that required significant investigation or response

Tip: Use your best estimate. The goal is directionally correct, not perfect.

OPERATIONAL LOSSES

Estimate the annual cost of work that failed to meet expectations the first time. Include the cost of correcting errors, recovering from delays, repairing damage, and restoring operations.

Examples include:

  • Rework
  • Delays
  • Downtime
  • Defects
  • Customer callbacks
  • Warranty work
  • Equipment damage
  • Material waste

Tip: Focus on the total business impact rather than calculating every individual cost.

LEADERSHIP TIME

Estimate the hidden cost of leaders spending time managing preventable problems instead of improving the business.

Include things like:

  • Incident investigations
  • Extra meetings
  • Resolving confusion
  • Supervisors pulled away from planned work
  • Repeat communication
  • Administrative follow-up

Tip: Consider the time spent by supervisors, managers, engineers, and support staff—not just frontline employees.

STEP 2

Estimate Potential Savings

Your total annual routine work costs have already been calculated.

Next, estimate what's possible if your organization systematically improved routine work. You don't need to be exact. Start with a conservative estimate. Even modest improvements can produce meaningful financial results.

For example:

  • 10% = modest improvement
  • 20% = meaningful improvement
  • 30% = significant improvement

The calculator will estimate the potential annual savings associated with that level of improvement.

STEP 3

Estimate Implementation Costs

Your estimated annual savings have already been calculated.

Now estimate the total investment required to improve routine work. Include one-time and ongoing costs such as:

  • Consulting or facilitation
  • Training materials or tools
  • Software or technology (if applicable)
  • Employee time spent participating in the process
  • Implementation and reinforcement activities

Multi-Year ROI

Many improvements continue generating savings long after implementation. Enter the number of years you'd like to project.

To project ROI beyond the first year, simply enter the number of years you’d like to include.

STEP 4

Cost Per Person

The Solution Investment (from Step 3) is automatically filled in.

Now, enter the number of employees who will participate in the program.

The calculator will then determine the cost per employee.