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Operational Performance Calculator โ€” Varnas Consulting

Operational Performance Calculator

The cost of not fixing it
is already running.

Every shift that underperforms against what the business is capable of is a cost that accrues quietly โ€” before agency, before NI, before missed output. Adjust the numbers to your operation and see what it's actually costing.

Baseline

Using average as the baseline. The loss is already baked into your numbers โ€” it just doesn't show as a line item. This is the conservative view.

Your operation
People per shiftShopfloor headcount
100
Shifts per day 2
Hours lost per shiftGap vs baseline
4.0h
Hourly rate (ยฃ)Average blended rate
ยฃ12.21
Agency / overtime premiumAbove base rate
25%
Cost of inaction
Per dayโ€”
Per weekโ€”
Per monthโ€”
Per quarterโ€”
Six-month running total
Labour only โ€” before NI, holiday pay, missed output, rework
โ€”
Cumulative labour loss over six months.
Three ways to realise the value
01 โ€” Cash it out
Reduce cost directly
Cut overtime, agency dependency, or headcount through natural attrition. Tangible, immediate, boardroom-ready.
โ€”recovered per year
02 โ€” Absorb growth
More output, same cost
Same people, more throughput. The capacity was already there โ€” it was leaking. No recruitment, no capex required.
โ€”shift-hours unlocked per year
03 โ€” Redeploy
Build change capability
The people developed become your internal change capability. They run the next initiative. That's where the compounding starts.
โ€”people-hours freed for improvement work per year

If the number looks familiar,
it's worth a conversation.

These numbers are conservative. They don't capture missed output, rework, customer service exposure, or the management time absorbed by firefighting.

A 30-minute call costs nothing. Leaving it another quarter has a price โ€” you've just calculated it.

Book a 30-minute call No pitch โ€” just an honest look at what's possible Or send a message โ†’