Waukesha, WI
130 employees · 2 lines · 10 machines
0
parts to replace ASAP
8
parts to replace soon
10
parts working
$1.0M–$2.5M
machine replacement value
CapEx cliff · next 5 years ($41,900–$92,660)
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)
$20,943
recurring savings we can audit (whole plant, extrapolated)
$4,189
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 $2,929 / yr → price $586 (range $87–$2,431). The whole-plant number scales this by the share of the plant the register covers.- Downtime avoided / yr$16,400expected value, range $3,534–$41,877 · odds from each part's health score · $81,211 of output at stake if the 1 line-stopper fail (99 h of stoppage) · not priced
- carrying cost avoided$9,812
- rush premiums avoided$4,580
- sister spare purchases avoided$471
- planned vs emergency$6,080
- spares inventory released (not priced) · one-time$46,725
Outages a sister-plant spare prevents (if it fails)
- PD-L1-M01-C3: spare PC-S001 from PC cuts 128 h down to 29 h · $81,211 at stake · 71% 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 |
|---|---|---|---|
| PD-L2-M02-C2 | 80–176 h | $29,050–$179k | PD-L2 stops if it fails; discontinued, age 27y; no spare: emergency buy from a listing |
| PD-L1-M02-C2 | 160–400 h | $10,500–$78,750 | PD-L1 stops if it fails; active, age 6y; no spare: emergency buy from a listing (capped at 10-25 operating days: repair, used unit or bypass) |
| PD-L2-M02-C1 | 64–224 h | $7,840–$76,832 | PD-L2 stops if it fails; discontinued, age 27y; no spare: emergency buy from a listing |
| PD-L1-M01-C2 | 160–400 h | $7,000–$52,500 | PD-L1 stops if it fails; active, age 8y; no spare: emergency buy from a listing (capped at 10-25 operating days: repair, used unit or bypass) |
| PD-L2-M01-C2 | 160–400 h | $6,300–$44,100 | PD-L2 stops if it fails; active, age 8y; no spare: emergency buy from a listing (capped at 10-25 operating days: repair, used unit or bypass) |
Line 1 · Case packer build
4 replace soonmachines worth $510k–$1.3M
| Machine | Parts | Risk | Replacement value | |
|---|---|---|---|---|
| Wexxar WFT case former line stopper packaging · built 2006 | 3 | Replace soon | $150k–$400k | details → |
| Dorner 3200 series line stopper conveyor · built 2020 | 2 | Replace soon | $40,000–$120k | details → |
| Fanuc R-2000iC weld cell robot cell · built 2008 | 2 | Replace soon | $250k–$500k | details → |
| Hytrol E24 accumulation conveyor · built 2017 | 2 | Replace soon | $40,000–$120k | details → |
| Miller PipePro welder other · built 1998 | 1 | Working | $30,000–$120k | details → |
Line 2 · Controls panel shop
4 replace soonmachines worth $510k–$1.3M
| Machine | Parts | Risk | Replacement value | |
|---|---|---|---|---|
| Douglas Machines Axiom case packer line stopper packaging · built 2018 | 3 | Replace soon | $150k–$400k | details → |
| Hytrol E24 accumulation line stopper conveyor · built 1999 | 2 | Replace soon | $40,000–$120k | details → |
| Yaskawa MH50 cell robot cell · built 2008 | 1 | Working | $250k–$500k | details → |
| Hytrol E24 accumulation conveyor · built 1999 | 3 | Replace soon | $40,000–$120k | details → |
| Miller PipePro welder other · built 2012 | 2 | Working | $30,000–$120k | details → |