CPG / Manufacturer Resources

Built for CPG Manufacturers and Plant Engineers

Free tools, calculators, and guides designed around the real challenges of running a packaging line - unplanned downtime, fault-finding time, MTTR, and the true cost of your current control systems.

Free Cost Calculators

Put a Number on the Problem

Downtime costs are almost always higher than the number on the maintenance report. These calculators help you build the full picture - and the business case for fixing it.

For CPG Engineering & Maintenance Teams

The Specification Gap Downtime
Cost Calculator

Most packaging line electrical downtime traces back to three specific gaps in the machine wiring specification. Terminal blocks, field-assembled connectors, and standard catalogue cables in dynamic applications are defaults your machine builder used when the specification left it to their discretion. This calculator helps you quantify what those gaps are costing your facility. If you have never run these numbers, what you find may change how you write your next machine purchase specification.

WHAT YOU GET

  • Total annual cost by fault category
  • Production loss versus maintenance labour search cost
  • Diagnosis time versus actual Mean Time To Repair
  • The business case for your next machine RFQ
Calculate Your Specification Gap Downtime Cost
For CPG Plant Managers & Engineers

The Field Connector Downtime
Cost Calculator

Every field connector fault on a packaging line costs you money, but most plant managers have never actually sat down and calculated exactly how much. This calculator walks you through the real numbers: your hourly production value, average fault frequency, mean time to repair, and the labour cost of your maintenance team. Plug in your own figures and see your annual downtime cost from field connector failures in black and white. For most plants, the number is a genuine eye-opener.

WHAT YOU GET

  • Annual downtime cost from connector-related faults
  • Cost per incident broken down by production loss and labour
  • Comparison against industry benchmarks
  • A clear ROI case for speccing factory overmolded connectors
Calculate Your Field Connector Downtime Cost

Sensor Wiring Labour Cost Calculator

Downloads

Free Practical Resources

Free Audit Checklist

Top 25 Connectivity Failure Points Checklist

The vast majority of electrical faults come from a small number of common failure points. This checklist gives you a practical guide to the top 25 culprits, from loose screw terminals to improper cable strain relief. Use it to audit your current machines or to design more robust systems from the start.

Get The Checklist
Free Assessment Tool

The Control System Complexity Scorecard

Is your control system simple and robust, or a ticking time bomb of complexity? This scorecard walks you through a 10-point evaluation of your current design, from cabinet layout to your I/O strategy. Get a clear, objective score and identify your biggest areas for improvement in just a few minutes.

Get the Assessment Tool
Free Reference

Startup & Commissioning Troubleshooting Map

Few things are more stressful than a machine that will not start properly. This free troubleshooting map walks you through the most common electrical and connectivity issues during commissioning and shows you how to solve them. Print it, keep it handy, and make your next startup smoother.

Get Troubleshooting Map
Industry Articles

The Connectivity Blog

Practical, engineering-grounded articles on optimizing machine connectivity, control system design, and reducing downtime. Click for More

01

The Top 5 Reasons Your Machine Startups Are Taking Too Long

Read This Article

02

Decentralized I/O: The Secret to Simpler, Cleaner Machine Designs

Read This Article

03

How to Slay the Downtime Dragon: A Guide for Plant Managers

Read This Article

04

Terminal Blocks vs. Connectors: A Practical Cost-Benefit Analysis

Read This Article

05

The Hidden Costs of Tribal Knowledge in Your Maintenance Department

Read This Article

06

A Step-by-Step Guide to Auditing Your Control Cabinet for Rework Risks

Read This Article

07

Why IP67 is Non-Negotiable for Reliable Machine Connectivity

Coming Soon...

08

How to Reduce Electrical Troubleshooting Time by 50%

Coming Soon...

09

Why Most Electrical Downtime Starts With One Loose Connection

Coming Soon...

10

The 30% Wiring Problem: Why So Much of Your Machine Build Is Still Manual Labour

Coming Soon...

11

Beyond the Bill of Materials: Calculating the True Cost of Complex Wiring

Coming Soon...

12

The Future of Machine Building: Is Your Team Ready for Plug-and-Play Automation?

Coming Soon...

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Ready for a Deeper Dive?

The free resources are a great start. But the Connectivity Chat is where the real work happens. Request yours today.

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