Free Tool · 5 min

Operational Cost Leak Calculator

Quantify the hidden waste in your operations — manual work, process failures, and avoidable costs — in 5 minutes.

Employees doing manual data work

People regularly doing manual data entry, copy-paste, reconciliation

Hours per employee per week

Time spent on purely manual tasks that could be automated

Average hourly cost (£)

Blended hourly cost including employer NI and benefits

Process errors or rework incidents per month

Mistakes requiring correction, returned orders, rework jobs

Average cost to fix each error (£)

Staff time + material cost + customer impact

Total inventory value (£)

Current stock value on hand

Estimated excess inventory (%)

Percentage held above optimal level due to poor visibility

Number of managers/directors

People who prepare or compile reports and management packs

Hours per manager per week on reporting

Time gathering data, chasing numbers, building reports

Average manager hourly cost (£)

Blended cost including salary, NI, and benefits