Published On: 28.05.2025Last Updated: 28.05.2025Categories: Articles

This article is the final part of the Secapp in the Manufacturing Industry serial. The three-part serial explores various ways Secapp’s critical communication and alerting solution supports manufacturing operations. You can read the first and second articles here and here.

Did you know?

Secapp helps save lives and manage critical operations during crisis situations.

  • Secapp is an award-winning critical communication and alerting service that enables you to reach all stakeholders important to your organization quickly and reliably. The security management of Secapp’s SaaS platform is ISO 27001:2022 certified (by Into Certification Oy).
  • Secapp eliminates communication bottlenecks, especially in situations requiring rapid response. With the solution, you can prepare for, alert, act during, and recover from disruptions and emergencies.
  • The system is designed to meet the needs of, among others, manufacturing industries, critical infrastructure, and public administration. Secapp works on all devices and offers multiple integration possibilities with systems used across different sectors. Learn more about Secapp’s user sectors and use cases.

1) ROI Example: Implementing Secapp in manufacturing

Unplanned production downtime, such as that caused by cyberattacks,  represents a major financial risk for manufacturing companies. This example looks at a company with 1,000 employees that experiences one major cyberattack-related outage per year. In reality, research suggests many such companies face multiple unplanned disruptions each month.

Baseline: cost estimates

According to ABB’s global study Value of Reliability (2023), one hour of unplanned downtime costs manufacturers approximately €116,000. Other sources, such as the article The Cost of Downtime by The 20, cite even higher figures. Siemens’ data suggests the average duration of a significant outage without automated communication or incident management is around 8 hours (Siemens 2023). This means a single annual outage could cost between €928,000 and €1,000,000.

Implementation and costs of Secapp

The company decides to implement Secapp’s alerting and critical communication solution to automate alerts, enable faster response, and maintain a real-time situational picture. The SaaS-based platform costs about €3 per user per month – around €3,000 monthly. First-year implementation, including training, totals about €41,000. From the second year on, annual costs drop to €36,000.

2) Where the time savings come from

Step 1: Alerting and Reaching Key Personnel

Without Secapp:

Calling or texting 20–50 key people manually:

  • Each call takes 2–3 minutes (call + conversation + notes)
  • For 30 people: 30 x 3 min = 90 min (1.5 hours)

Total time to reach all: At least 1.5 hours (150–180 minutes)

With Secapp:

Automated alert sent to all key contacts:

  • All recipients are notified within 30–60 seconds
  • Escalation if no response, confirmation required
  • Real-time updates and logging

Total time to reach all: maximum 5-10 minutes

Step 2: Incident Monitoring and Communication

Without Secapp:

Ongoing phone calls and updates to share information:

  • Status updates by phone: 30-60 min per round
  • Typically 2-3 rounds = 1–3 hours
  • Text/email updates: 20–30 min per round

Total update time: 1.5-3.5 hours

With Secapp:

Centralized, real-time situational view in Secapp:

  • Automatic updates with no need for manual communication loops
  • Instant information sharing across teams and stakeholders

Time saved: 1-3 hours

Total time saved with Secapp: 3-5 hours per incident

3) Impact of Secapp implementation

With Secapp, the response time for incidents drops significantly. In this scenario, the outage duration is conservatively reduced from 8 to 5 hours. Using the earlier estimate of €116,000 per hour, this reduces total downtime cost from €928,000 to €580,000.

This means that the annual cost savings is 348,000 euros.

4) ROI Calculation (Return on invest)

 

First year:

Cost of Secapp: €41,000

  • Savings: €348,000
  • ROI: ~749%

Second and subsequent years:

Annual Cost of Secapp: €36,000

  • Savings: €348,000
  • ROI: ~867%

Even with a single annual outage, adopting Secapp results in a substantial financial benefit. The investment pays for itself many times over in the first year alone.

“Those Numbers Are Unrealistic for a Company Our Size.”

It’s true that these figures are illustrative. However, the value remains strong even when scaled to smaller units. Let’s downscale this example to a 100-person unit:

  • Downtime cost per hour: €116,000 →  €11,600
  • Cost for 8-hour outage: €11,600/h x 8 = €92,800
  • Cut that in half for caution: €46,400
  • Assume Secapp costs are slightly higher due to smaller volume: monthly: €460. Setup/training is less than €1,000

And now, let’s make a new calculation

With Secapp, the response time to a production outage is significantly reduced. In this example, it is assumed that the duration of the disruption is reduced from an average of 8 hours to 5 hours, but in reality, the duration of the disruption can be reduced significantly more with Secapp when all indirect time savings are taken into account. A conservative estimate would reduce the annual cost of a disruption to approximately 29,000 euros (5,800 € x 5 = 29,000 €). This means that the annual savings achieved with Secapp are approximately 17,400 euros.

ROI Calculation

First year:

Secapp´s total cost: €6,500

  • Savings: €17,400
  • ROI: approximately 268%

Following years:

The cost of Secapp: €5,500

  • Savings: €17,400
  • ROI: approximately 316%

Final thought

Even for smaller manufacturing operations, Secapp delivers significant ROI – paying for itself in under a year.

*Note: Pricing in this example is simplified for clarity, using a cost of 3€ / user . Actual costs depend on user count, selected features, integrations, and other client-specific factors.

Interested to know more?

Let’s talk about how you could benefit from Secapp.

This article is the final part of the Secapp in the Manufacturing Industry serial. The three-part serial explores various ways Secapp’s critical communication and alerting solution supports manufacturing operations. You can read the first and second articles here and here.

Did you know?

Secapp helps save lives and manage critical operations during crisis situations.

  • Secapp is an award-winning critical communication and alerting service that enables you to reach all stakeholders important to your organization quickly and reliably. The security management of Secapp’s SaaS platform is ISO 27001:2022 certified (by Into Certification Oy).
  • Secapp eliminates communication bottlenecks, especially in situations requiring rapid response. With the solution, you can prepare for, alert, act during, and recover from disruptions and emergencies.
  • The system is designed to meet the needs of, among others, manufacturing industries, critical infrastructure, and public administration. Secapp works on all devices and offers multiple integration possibilities with systems used across different sectors. Learn more about Secapp’s user sectors and use cases.

1) ROI Example: Implementing Secapp in manufacturing

Unplanned production downtime, such as that caused by cyberattacks,  represents a major financial risk for manufacturing companies. This example looks at a company with 1,000 employees that experiences one major cyberattack-related outage per year. In reality, research suggests many such companies face multiple unplanned disruptions each month.

Baseline: cost estimates

According to ABB’s global study Value of Reliability (2023), one hour of unplanned downtime costs manufacturers approximately €116,000. Other sources, such as the article The Cost of Downtime by The 20, cite even higher figures. Siemens’ data suggests the average duration of a significant outage without automated communication or incident management is around 8 hours (Siemens 2023). This means a single annual outage could cost between €928,000 and €1,000,000.

Implementation and costs of Secapp

The company decides to implement Secapp’s alerting and critical communication solution to automate alerts, enable faster response, and maintain a real-time situational picture. The SaaS-based platform costs about €3 per user per month – around €3,000 monthly. First-year implementation, including training, totals about €41,000. From the second year on, annual costs drop to €36,000.

2) Where the time savings come from

Step 1: Alerting and Reaching Key Personnel

Without Secapp:

Calling or texting 20–50 key people manually:

  • Each call takes 2–3 minutes (call + conversation + notes)
  • For 30 people: 30 x 3 min = 90 min (1.5 hours)

Total time to reach all: At least 1.5 hours (150–180 minutes)

With Secapp:

Automated alert sent to all key contacts:

  • All recipients are notified within 30–60 seconds
  • Escalation if no response, confirmation required
  • Real-time updates and logging

Total time to reach all: maximum 5-10 minutes

Step 2: Incident Monitoring and Communication

Without Secapp:

Ongoing phone calls and updates to share information:

  • Status updates by phone: 30-60 min per round
  • Typically 2-3 rounds = 1–3 hours
  • Text/email updates: 20–30 min per round

Total update time: 1.5-3.5 hours

With Secapp:

Centralized, real-time situational view in Secapp:

  • Automatic updates with no need for manual communication loops
  • Instant information sharing across teams and stakeholders

Time saved: 1-3 hours

Total time saved with Secapp: 3-5 hours per incident

3) Impact of Secapp implementation

With Secapp, the response time for incidents drops significantly. In this scenario, the outage duration is conservatively reduced from 8 to 5 hours. Using the earlier estimate of €116,000 per hour, this reduces total downtime cost from €928,000 to €580,000.

This means that the annual cost savings is 348,000 euros.

4) ROI Calculation (Return on invest)

 

First year:

Cost of Secapp: €41,000

  • Savings: €348,000
  • ROI: ~749%

Second and subsequent years:

Annual Cost of Secapp: €36,000

  • Savings: €348,000
  • ROI: ~867%

Even with a single annual outage, adopting Secapp results in a substantial financial benefit. The investment pays for itself many times over in the first year alone.

“Those Numbers Are Unrealistic for a Company Our Size.”

It’s true that these figures are illustrative. However, the value remains strong even when scaled to smaller units. Let’s downscale this example to a 100-person unit:

  • Downtime cost per hour: €116,000 →  €11,600
  • Cost for 8-hour outage: €11,600/h x 8 = €92,800
  • Cut that in half for caution: €46,400
  • Assume Secapp costs are slightly higher due to smaller volume: monthly: €460. Setup/training is less than €1,000

And now, let’s make a new calculation

With Secapp, the response time to a production outage is significantly reduced. In this example, it is assumed that the duration of the disruption is reduced from an average of 8 hours to 5 hours, but in reality, the duration of the disruption can be reduced significantly more with Secapp when all indirect time savings are taken into account. A conservative estimate would reduce the annual cost of a disruption to approximately 29,000 euros (5,800 € x 5 = 29,000 €). This means that the annual savings achieved with Secapp are approximately 17,400 euros.

ROI Calculation

First year:

Secapp´s total cost: €6,500

  • Savings: €17,400
  • ROI: approximately 268%

Following years:

The cost of Secapp: €5,500

  • Savings: €17,400
  • ROI: approximately 316%

Final thought

Even for smaller manufacturing operations, Secapp delivers significant ROI – paying for itself in under a year.

*Note: Pricing in this example is simplified for clarity, using a cost of 3€ / user . Actual costs depend on user count, selected features, integrations, and other client-specific factors.

Interested to know more?

Let’s talk about how you could benefit from Secapp.