Lima, OH
140 employees · 2 lines · 10 machines
1
parts to replace ASAP
4
parts to replace soon
9
parts working
$1.1M–$2.6M
machine replacement value
CapEx cliff · next 5 years ($47,753–$140k)
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)
$23,236
recurring savings we can audit (whole plant, extrapolated)
$4,647
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 $3,018 / yr → price $604 (range $86–$2,511). The whole-plant number scales this by the share of the plant the register covers.- Downtime avoided / yr$11,454expected value, range $0–$35,243 · odds from each part's health score · $46,922 of output at stake if the 1 line-stopper fail (55 h of stoppage) · not priced
- carrying cost avoided$10,568
- rush premiums avoided$4,940
- sister spare purchases avoided$902
- planned vs emergency$6,825
- spares inventory released (not priced) · one-time$50,325
Outages a sister-plant spare prevents (if it fails)
- PC-L2-M01-C2: spare PA-S001 from PA cuts 84 h down to 29 h · $46,922 at stake · 85% 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 |
|---|---|---|---|
| PC-L2-M02-C3 | 112–400 h | $4,851–$47,250 | PC-L2 stops if it fails; unknown, age 9y; no spare: new-unit lead time (capped at 10-25 operating days: repair, used unit or bypass) |
| PC-L1-M02-C1 | 160–400 h | $3,850–$28,000 | PC-L1 stops if it fails; active, age 10y; no spare: emergency buy from a listing (capped at 10-25 operating days: repair, used unit or bypass) |
| PC-L2-M01-C2 | 18–40 h | $4,071–$24,675 | PC-L2 stops if it fails; discontinued, age 17y; ship spare PA-S001 from PA and swap |
| PC-L2-M02-C2 | 40–128 h | $2,310–$20,160 | PC-L2 stops if it fails; discontinued, age 9y; no spare: emergency buy from a listing |
| PC-L1-M01-C1 | 2–8 h | $953–$11,088 | PC-L1 stops if it fails; discontinued, age 26y; swap in shelf spare PC-S002 |
Line 1 · Machining
1 replace ASAPmachines worth $710k–$1.7M
| Machine | Parts | Risk | Replacement value | |
|---|---|---|---|---|
| Haas VF-4 line stopper cnc mill · built 2000 | 1 | Replace ASAP | $180k–$420k | details → |
| Okuma LB3000 EX line stopper cnc lathe · built 2016 | 1 | Working | $160k–$380k | details → |
| Okuma MB-46VAE cnc mill · built 2020 | 1 | Working | $180k–$420k | details → |
| Haas ST-30 cnc lathe · built 2018 | 2 | Working | $160k–$380k | details → |
| Miller PipePro welder other · built 2013 | 1 | Working | $30,000–$120k | details → |
Line 2 · Heat treat + finish
4 replace soonmachines worth $350k–$930k
| Machine | Parts | Risk | Replacement value | |
|---|---|---|---|---|
| Lindberg batch furnace line stopper oven · built 2009 | 2 | Replace soon | $120k–$300k | details → |
| Lindberg batch furnace line stopper oven · built 2017 | 3 | Working | $120k–$300k | details → |
| Dorner 3200 series conveyor · built 1999 | 2 | Replace soon | $40,000–$120k | details → |
| Mitutoyo Crysta CMM other · built 2004 | 1 | Working | $30,000–$120k | details → |
| Ingersoll Rand R37i compressor · built 2004 | 2 | Replace soon | $40,000–$90,000 | details → |