State of the Industry
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Many suppliers were liquidated in the recession but eventual volume rebound will cause liquidity issues.
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Metal costs are subject to major commodity swings – world demand, import restrictions, scrap metal costs.
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It's critical to have effective cost escalator clause in any customer contract, especially LTAs.
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Migration of steel to plastics may have stopped due to increased oil price volatility.
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Customer alternatives may now be less such that suppliers have renewed pricing power.
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Machining continues to replace foundry products.
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Stamping and machining rollups have been attempted without success - this remains mostly a local market business.
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Machining segment is increasingly high-tech.
$150 billion dollar industry made up of the following segments:
Iron and steel mills - high concentration of revenue among the four largest players with fierce international competition
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Automotive and construction demand is highly volatile in this segment
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Keys to compete: sales contracts, global reach, differentiated products
Pipe and tube - moderate concentration of revenue among the four largest players; consolidation increasing slowly
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Keys to compete: cost-lowering technology , diverse client base, relationship with steel manufacturers
Stamping and forging - highly fragmented; ripe for consolidation
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Almost 60% of demand originates from the Automotive and Aircraft businesses
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Keys to compete: global expansion, integrated supply systems, cost leverage
Hand-tool and cutlery - fragmented, increasing opportunity for consolidation
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Keys to compete: premium brand/product offerings, export markets, extensive distribution
Machine shop services - highly fragmented, relatively low barriers to entry, slow integration with former customers
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Keys to compete: technology, loyal customer base, access to skilled workforce
6- to 12-month Outlook
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After 2010 recovery, growth generally expected through 2015
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Near term: government intervention crucial to restoring business/consumer confidence to restart downstream demand
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Headwinds include fierce global competition and competition from other materials
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Commodity manufacturers need to integrate value added services to protect work
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Mexican capacity is an option to consider
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Eventually, metals will be molded like injection molding via metal powders; this will revolutionize the industry when technology evolution drives costs down.
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Demand for high performance metals such as aluminum and magnesium in aerospace and medical products will increase.
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Foundry capacity will be in short supply as the economy recovers long term - capacity has been shut and environmental regulations make it extremely difficult to open a new foundry.