Fort Wayne, IN

180 employees · 3 lines · 14 machines

parts to replace ASAP

parts to replace soon

parts working

$2.4M–$5.4M

machine replacement value

CapEx cliff · next 5 years ($51,563–$145k)

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)

$29,016

recurring savings we can audit (whole plant, extrapolated)

$5,803

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 $4,103 / yr → price $821 (range $138–$3,290). The whole-plant number scales this by the share of the plant the register covers.

Downtime avoided / yr$29,657
expected value, range $5,264–$79,109 · odds from each part's health score · $172k of output at stake if the 2 line-stoppers fail (210 h of stoppage) · not priced
carrying cost avoided$13,577
rush premiums avoided$6,350
sister spare purchases avoided$3,211
planned vs emergency$5,879
spares inventory released (not priced) · one-time$64,650

Outages a sister-plant spare prevents (if it fails)

PB-L3-M01-C1: spare PA-S006 from PA cuts 184 h down to 29 h · $127k at stake · 49% chance in 3 yrs
PB-L3-M01-C3: spare PA-S001 from PA cuts 84 h down to 29 h · $45,117 at stake · 94% 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
PB-L3-M01-C2	80–208 h	$21,000–$164k	PB-L3 stops if it fails; discontinued, age 16y; no spare: emergency buy from a listing
PB-L1-M02-C3	40–128 h	$16,800–$161k	PB-L1 stops if it fails; active, age 7y; no spare: emergency buy from a listing
PB-L3-M01-C4	112–400 h	$11,270–$121k	PB-L3 stops if it fails; unknown, age 19y; no spare: new-unit lead time (capped at 10-25 operating days: repair, used unit or bypass)
PB-L1-M02-C2	160–400 h	$13,300–$99,750	PB-L1 stops if it fails; active, age 11y; no spare: emergency buy from a listing (capped at 10-25 operating days: repair, used unit or bypass)
PB-L3-M02-C2	160–400 h	$7,700–$57,750	PB-L3 stops if it fails; active, age 5y; no spare: emergency buy from a listing (capped at 10-25 operating days: repair, used unit or bypass)

Line 1 · Stamping

1 replace ASAP2 replace soonmachines worth $1.2M–$2.5M

Machine	Parts	Risk	Replacement value
Komatsu OBS 150-2 line stopper press · built 2017	2	Working	$450k–$900k	details →
Minster P2-200 line stopper press · built 2013	3	Replace ASAP	$450k–$900k	details →
Fanuc R-2000iC weld cell robot cell · built 2012	1	Working	$250k–$500k	details →
Hytrol E24 accumulation conveyor · built 2013	3	Replace soon	$40,000–$120k	details →
Ingersoll Rand R37i compressor · built 2021	2	Working	$40,000–$90,000	details →

Line 2 · Machining

1 replace soonmachines worth $710k–$1.7M

Machine	Parts	Risk	Replacement value
Haas VF-4 line stopper cnc mill · built 2013	2	Working	$180k–$420k	details →
Haas ST-30 line stopper cnc lathe · built 2017	1	Working	$160k–$380k	details →
Okuma MB-46VAE cnc mill · built 2001	1	Replace soon	$180k–$420k	details →
Haas ST-30 cnc lathe · built 2007	1	Working	$160k–$380k	details →
Mitutoyo Crysta CMM other · built 2002	1	Working	$30,000–$120k	details →

Line 3 · Assembly

6 replace soonmachines worth $480k–$1.1M

Machine	Parts	Risk	Replacement value
Wexxar WFT case former line stopper packaging · built 2007	4	Replace soon	$150k–$400k	details →
Hytrol E24 accumulation line stopper conveyor · built 2021	2	Working	$40,000–$120k	details →
Yaskawa MH50 cell robot cell · built 2010	2	Replace soon	$250k–$500k	details →
Hytrol E24 accumulation conveyor · built 2008	2	Replace soon	$40,000–$120k	details →