Revenue is $112 million from two plants with 180 CNC machines, and EBITDA margin is 7.2%. One off-highway equipment maker accounts for 34% of sales under an agreement with a 2% annual price reduction; the top three customers account for 61%. On-time delivery to the promised date is 82%, with $6.8 million of orders past due and $1.9 million a year spent on premium freight. Overall equipment effectiveness on the 14 horizontal machining cells is 54%, mostly lost to setups that average 95 minutes. Scrap and rework cost 4.6% of sales, 28 direct positions are open, and overtime is 16% of hours.
Challenges- Capacity is short on paper and idle in practice. The cells produce good parts for 54% of scheduled time while the schedule is rebuilt by hand every morning around late material and hot orders.
- Of 1,900 active part numbers, 620 bring in 6% of revenue at a negative margin and consume a fifth of all setups.
- Half of the 41 machinists who can set up a five-axis job are over 55, and 46% of new operators leave within their first year.
We will focus on- Delivery reliability first, because late orders block every conversation about price and new work.
- More output from the 180 machines we own before buying another.
- Complex, documented parts for medical and laboratory equipment makers, where our tolerances are worth paying for.
We will not- A third plant or a building extension. Machine hours freed by shorter setups cover the growth in this plan.
- Replacing the ERP system. It is dated, but a replacement would absorb the same people who must fix scheduling and setups.
- Quoting high-volume automotive work, even to fill machines. Its price levels and annual reductions would repeat the problem we already have.