Oshkosh, WI
100 employees · 2 lines · 8 machines
1
parts to replace ASAP
10
parts to replace soon
6
parts working
$960k–$2.3M
machine replacement value
CapEx cliff · next 5 years ($84,489–$245k)
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)
$27,325
recurring savings we can audit (whole plant, extrapolated)
$5,465
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 $3,975 / yr → price $795 (range $159–$2,919). The whole-plant number scales this by the share of the plant the register covers.- Downtime avoided / yr$51,450expected value, range $11,698–$129k · odds from each part's health score · $320k of output at stake if the 4 line-stoppers fail (500 h of stoppage) · not priced
- carrying cost avoided$7,544
- rush premiums avoided$3,530
- sister spare purchases avoided$4,788
- planned vs emergency$11,463
- spares inventory released (not priced) · one-time$35,925
Outages a sister-plant spare prevents (if it fails)
- PF-L1-M02-C1: spare PD-S004 from PD cuts 160 h down to 29 h · $85,969 at stake · 49% chance in 3 yrs
- PF-L2-M01-C1: spare PD-S002 from PD cuts 160 h down to 29 h · $81,670 at stake · 45% chance in 3 yrs
- PF-L2-M02-C1: spare PD-S004 from PD cuts 160 h down to 29 h · $81,670 at stake · 36% 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 |
|---|---|---|---|
| PF-L1-M01-C4 | 112–400 h | $30,968–$332k | PF-L1 stops if it fails; unknown, age 28y; no spare: new-unit lead time (capped at 10-25 operating days: repair, used unit or bypass) |
| PF-L2-M01-C2 | 64–208 h | $12,320–$110k | PF-L2 stops if it fails; discontinued, age 15y; no spare: emergency buy from a listing |
| PF-L2-M01-C3 | 160–400 h | $13,440–$92,400 | PF-L2 stops if it fails; active, age 7y; no spare: emergency buy from a listing (capped at 10-25 operating days: repair, used unit or bypass) |
| PF-L2-M02-C2 | 160–400 h | $6,720–$46,200 | PF-L2 stops if it fails; active, age 7y; no spare: emergency buy from a listing (capped at 10-25 operating days: repair, used unit or bypass) |
| PF-L1-M01-C2 | 18–40 h | $5,922–$39,480 | PF-L1 stops if it fails; discontinued, age 25y; ship spare PD-S001 from PD and swap |
Line 1 · Conveyor fabrication
1 replace ASAP6 replace soonmachines worth $480k–$1.1M
| Machine | Parts | Risk | Replacement value | |
|---|---|---|---|---|
| Douglas Machines Axiom case packer line stopper packaging · built 1998 | 4 | Replace ASAP | $150k–$400k | details → |
| Hytrol E24 accumulation line stopper conveyor · built 2006 | 2 | Replace soon | $40,000–$120k | details → |
| Yaskawa MH50 cell robot cell · built 2014 | 3 | Replace soon | $250k–$500k | details → |
| Hytrol E24 accumulation conveyor · built 2009 | 2 | Replace soon | $40,000–$120k | details → |
Line 2 · Final assembly
4 replace soonmachines worth $480k–$1.1M
| Machine | Parts | Risk | Replacement value | |
|---|---|---|---|---|
| Wexxar WFT case former line stopper packaging · built 2005 | 3 | Replace soon | $150k–$400k | details → |
| Hytrol E24 accumulation line stopper conveyor · built 2010 | 2 | Replace soon | $40,000–$120k | details → |
| Yaskawa MH50 cell robot cell · built 2007 | 2 | Working | $250k–$500k | details → |
| Dorner 3200 series conveyor · built 2021 | 2 | Working | $40,000–$120k | details → |