Toledo, OH
220 employees · 3 lines · 16 machines
3
parts to replace ASAP
15
parts to replace soon
16
parts working
$3.7M–$7.7M
machine replacement value
CapEx cliff · next 5 years ($94,963–$257k)
Dark = low estimate, light = up to high estimate. Control-part replacements + migration engineering. How we got this: Sources page.
Savings and our fee (per year)
$48,582
recurring savings we can audit (whole plant, extrapolated)
$9,716
registry subscription per year (fixed fee, tiered by the number of critical parts)
+ one-time onboarding $1–2k · sensors: monthly fee per monitored point (price to set) · customer payback 2.4 months. The fee stays fixed whatever we report, so we never judge our own fee.
Evidence: only the parts scanned so far
savings $6,424 / yr → price $1,285 (range $258–$4,713). The whole-plant number scales this by the share of the plant the register covers.- Downtime avoided / yr$77,330expected value, range $11,805–$205k · odds from each part's health score · $622k of output at stake if the 4 line-stoppers fail (668 h of stoppage) · not priced
- carrying cost avoided$16,585
- rush premiums avoided$7,760
- sister spare purchases avoided$10,515
- planned vs emergency$13,722
- spares inventory released (not priced) · one-time$78,975
Outages a sister-plant spare prevents (if it fails)
- PA-L3-M01-C2: spare PC-S009 from PC cuts 280 h down to 29 h · $231k at stake · 30% chance in 3 yrs
- PA-L3-M02-C2: spare PC-S009 from PC cuts 280 h down to 29 h · $231k at stake · 25% chance in 3 yrs
- PA-L2-M01-C1: spare PB-S001 from PB cuts 112 h down to 29 h · $84,427 at stake · 100% chance in 3 yrs
Downtime avoided above = expected value of these over 3 years, per year, scanned parts only. Not in the price.
Line stoppers · downtime exposure per year (failure odds × hours down × $/hour × share not made up later)
| Part | Hours down if it fails | Exposure / year | Why |
|---|---|---|---|
| PA-L1-M01-C4 | 160–400 h | $83,160–$624k | PA-L1 stops if it fails; discontinued, age 24y; no spare, no listings: successor lead time + migration (capped at 10-25 operating days: repair, used unit or bypass) |
| PA-L2-M01-C2 | 80–208 h | $37,310–$269k | PA-L2 stops if it fails; discontinued, age 22y; no spare: emergency buy from a listing |
| PA-L1-M01-C3 | 40–128 h | $20,160–$194k | PA-L1 stops if it fails; active, age 9y; no spare: emergency buy from a listing |
| PA-L2-M02-C2 | 80–208 h | $24,570–$177k | PA-L2 stops if it fails; discontinued, age 20y; no spare: emergency buy from a listing |
| PA-L2-M01-C1 | 18–40 h | $10,135–$62,370 | PA-L2 stops if it fails; discontinued, age 18y; ship spare PB-S001 from PB and swap |
Line 1 · Progressive stamping
2 replace ASAP5 replace soonmachines worth $1.3M–$2.6M
| Machine | Parts | Risk | Replacement value | |
|---|---|---|---|---|
| Komatsu OBS 150-2 line stopper press · built 2002 | 4 | Replace ASAP | $450k–$900k | details → |
| Minster P2-200 line stopper press · built 2000 | 2 | Replace soon | $450k–$900k | details → |
| Yaskawa MH50 cell robot cell · built 2003 | 1 | Working | $250k–$500k | details → |
| Hytrol E24 accumulation conveyor · built 2006 | 2 | Replace soon | $40,000–$120k | details → |
| Ingersoll Rand R37i compressor · built 2002 | 2 | Replace soon | $40,000–$90,000 | details → |
| Mitutoyo Crysta CMM other · built 2002 | 1 | Working | $30,000–$120k | details → |
Line 2 · Servo press + assembly
1 replace ASAP7 replace soonmachines worth $1.2M–$2.5M
| Machine | Parts | Risk | Replacement value | |
|---|---|---|---|---|
| Aida NC1-200 servo line stopper press · built 2008 | 3 | Replace ASAP | $450k–$900k | details → |
| Minster P2-200 line stopper press · built 2006 | 3 | Replace soon | $450k–$900k | details → |
| Fanuc R-2000iC weld cell robot cell · built 1998 | 1 | Replace soon | $250k–$500k | details → |
| Hytrol E24 accumulation conveyor · built 2013 | 2 | Replace soon | $40,000–$120k | details → |
| Atlas Copco GA 37 compressor · built 1998 | 2 | Replace soon | $40,000–$90,000 | details → |
Line 3 · Weld and finish
3 replace soonmachines worth $1.2M–$2.5M
| Machine | Parts | Risk | Replacement value | |
|---|---|---|---|---|
| Minster P2-200 line stopper press · built 2008 | 3 | Replace soon | $450k–$900k | details → |
| Minster P2-200 line stopper press · built 2012 | 2 | Working | $450k–$900k | details → |
| Yaskawa MH50 cell robot cell · built 2008 | 3 | Replace soon | $250k–$500k | details → |
| Dorner 3200 series conveyor · built 2012 | 2 | Replace soon | $40,000–$120k | details → |
| Ingersoll Rand R37i compressor · built 2020 | 2 | Working | $40,000–$90,000 | details → |