Professional Documents
Culture Documents
Table of Contents
Introduction 02
NEW THIS YEAR 04
SELECT 2013 SURVEY Results
06
TRENDS 09
Trend 1 Company Performance Trends
10
12
14
16
20
In Closing 22
Partial List of Information Provided
to Survey Participants in Full Report
24
Notice
Plante Moran has
exercised professional care and diligence in preparing this report. However, because the data used
in this report comes from third-party sources and Plante Moran has not independently verified, validated, or audited
any such data, Plante Moran makes no representations or warranties with respect to the accuracy of the information
contained in this report. Plante Moran shall not be liable to any client or any other person or entity for any inaccuracy
or inauthenticity of the information contained in this report or for any errors or omissions in its content, regardless of
the cause of such inaccuracy, inauthenticity, error, or omission. Furthermore, in no event shall Plante Moran be liable
for consequential, incidental, or punitive damages to any person or entity in any manner relating to this report.
Introduction
We are pleased to present the 2013 North American Plastics Industry Summary Report.
Since 1995, Plante Moran has led this study, which serves to gather and analyze the most
empirical data collected in the plastics processing industry in North America.
Participation
Sales force
structure data
Value proposition
analytics
such as:
Compensation
programs for
sales, marketing
activity
Planning process
utilized
Management
team data
Complexity
management
Value ranking
assessment
Press hours
statistics
++ Uniqueness of process
++ Product development
capabilities
++ Assessment of competitive
environment
Perhaps most importantly, we have added a value ranking assessment that reviews
the various components of value and assigns you a score for comparability and to
calculate your companys relative value.
We appreciate the continued support of all those who participated, including the
continued assistance of the Manufacturers Association for Plastics Processors in
making this survey the benchmark of the plastics processing industry.
For comparison purposes, we aligned the AVERAGE of the statement of operations and the MEDIAN of select benchmarking
analytics versus the successful company performance.
Mean Data by Sales Quartile
<$12.8 Million
>$29.8 Million
Successful
Company1
96.4%
98.3%
98.1%
99.0%
98.5%
7.2%
7.8%
5.8%
3.7%
3.9%
(4.0%)
(6.9%)
(4.0%)
(3.0%)
(2.7%)
0.4%
0.9%
0.2%
0.2%
0.3%
100.0%
100.0%
100.0%
100.0%
100.0%
25.3%
33.9%
33.4%
36.7%
24.1%
Purchased Components
7.1%
5.7%
12.1%
10.2%
10.4%
3.7%
2.4%
2.1%
5.1%
2.6%
Direct Labor
11.8%
10.7%
7.3%
8.3%
7.8%
Overhead Costs
25.7%
26.7%
25.7%
23.1%
24.3%
73.6%
79.4%
80.6%
83.4%
69.2%
Gross Profit
26.4%
20.5%
19.3%
16.6%
30.7%
18.3%
12.8%
11.3%
10.8%
13.7%
Operating Income
8.0%
7.8%
8.0%
5.8%
17.1%
$2.06
$2.04
$2.58
$2.59
$3.02
54,720
384,825
209,908
1,514,700
3,042,600
36%
42%
35%
48%
40%
15%
11%
13%
14%
15%
2011/2012 Data
Sales
Production Sales
Tooling Sales
Less: Tooling COGS
Other Operating Revenue
Total Sales
Cost of Sales
Raw Materials
1. A Successful Company exceeds 10% return on sales (before interest, taxes, and owners compensation), return on assets of 15%, and sales
growth of greater than 5%
2. Value Add per Labor Dollar = (Sales Purchased Materials)/Total Labor
3. Complexity equals frequently used resins x (active molds
+ inserts) x presses
A resurgence in Mexico
TRENDS
2013 North American Plastics Industry Study
10
compensation), return on
assets in excess of 15%, and
sales growth greater than 5%.
In most years, fewer than 8%
of the survey respondents meet
this criteria; however, this
year, 16% of the respondents
met this criteria.
Cum. GP change
22.9%
8.4%
2011
2012
6.9%
2011
2012
2011
2012
Higher productivity
Higher profits
Higher utilization
Labor productivity as
measured by value-add
(sales less material and
outside processing) divided
by total full-time equivalents
significantly jumped in
2012. As we all learned,
during the depth of the
recession, companies were
forced to figure out how do
more with less. It appears
that many processors have
Press utilization
increased for the
third straight year.
has brought pricing discipline
to the industry. Interestingly, it
appears the growth is strategic
with a modest reduction in
average complexity levels,
meaning some low volume
customers were priced out of
the company.
11
A Resurgence in Mexico
The following points highlight some of the facts that are contributing to Mexicos recent
positive business trends:
$12.6 billion
Record levels
27
19
$5.00
Average loaded
hourly wage rate
for manufacturing
operators
Booming industries in Mexico that are driving higher demand for plastics
AEROSPACE
APPLIANCE
AUTOMOTIVE
ELECTRONICS
12
3.4%
2%
1.9%
1.5%
0
-2%
Mexico
USa
-4%
-6%
Canada
2011
2012
2013
source:INEGI
While we have seen the U.S. nicely recover from the great recession, Mexico has experienced an
even stronger recovery, averaging approximately 4% GDP growth since 2010. We are seeing a
related increased level of expansion and migration of plastics companies into this country.
Tooling companies, crane companies, and other supporting businesses are slowly
but surely starting to expand or set up operations in support of this movement.
Goldman Sachs is
Our advice to our clients is that whether or not you are or plan to be in Mexico,
predicting Mexico to be
your strategy needs to include how your organization will operate in lieu of the
the worlds 5th largest
business dynamics created by Mexicos resurgence. If you need more long-term
economy by 2050.
motivation to have your plans include a Mexico strategy, consider that Goldman
Sachs is predicting Mexico to be the worlds fifth largest economy by 2050.
13
Continued socio-economic
growth of developing nations
14
We continue to see the gap reduced among costs to operate injection molding machines in the U.S.,
Mexico, and China. This is driven partly by the recent reduction of energy costs in the U.S. and rising
land values in certain markets including Mexico and China. The result of these conditions is that the
cost to operate machines in the U.S. is becoming more globally competitive, in particular, with large
machines. For the past several years, Plante Moran has prepared press rates for various geographic
regions based on inputs from local labor, utility, and real estate sources. Your rates may differ based
on your inputs specific to your operation.
Indiana
Mexico
East
Mexico
Interior
China
Interior
China
Shanghai
200
$ 41.57
$45.91
$43.63
$29.50
$37.35
1000
$82.42
$97.42
$95.94
$76.14
$89.50
3000
$146.40
$178.66
$176.10
$139.59
$157.86
Economists and energy experts expect the U.S. to continue to have a sizable advantage in its costs
for energy over the next several years. While we expect that plastics applications requiring relatively
high labor content will continue to reap the benefits of being produced in nations
Experts expect the
with lower labor costs than the U.S., we expect U.S.- based plastics processors
U.S. to have a sizable
producing applications with relatively low labor content will continue to take on
more work that was formerly produced in foreign countries. For new programs,
advantage in regard to
we expect less work that has a final destination of the U.S. to be sourced to
energy costs over the
processors in foreign countries as compared to the recent past.
15
Investors eager to enter or further invest in the plastics space are creating exit opportunities
for owners, and they have a renewed appetite for businesses in plastics and packaging. P&M
Corporate Finance (Plante Morans investment banking affiliate) reports that a total of 1,463
plastics and packaging deals were completed between 20092012. It further notes that increased
levels of M&A activity during Q2 and Q3 of 2013 indicate continued robust interest in this space,
which bodes well for the potential for similar levels of M&A activity to continue for the next
several quarters. Sellers, including retiring entrepreneurs without a second generation operator,
are realizing attractive current pricing multiples.
In addition, private equity
investors are reaching
inflection points in their
Strategic buyers
comprise the
majority of buying
activity, completing
approximately 50%
more transactions than
financial buyers.
400
350
Number of Deals
300
250
393
340
80
67
347
60
72
57
61
383
80
68
200
266
150
100
199
218
235
50
0
2009
2010
2011
2012
investment cycles where
they desire to exit and
Strategic
Financial Platform
Financial Add-On
provide returns to their
sources of capital. Add-ons remain an important tool in value creation, with activity driven by
surplus capital. Interestingly, strategic buyers comprise the majority of buying activity, completing
approximately 50% more transactions than financial buyers.
For more information on M&A activity, please visit pmcf.com.
16
The exit window may start looking attractive for those with strong current performance and a
bunch of bumps and bruises from the last recession.
However...
Are you ready for the beauty contest to attract top dollar?
How truly unique are your manufacturing skills?
Do you have acknowledged project and/or design skills
that are admired by your customers?
How competitive are you in the industry?
17
18
Want to participate?
Visit plastics.plantemoran.com
Already a participant?
Review your customized
benchmarking report and
identify where you stand
in the industry.
19
Plante Morans plastics practice is widely recognized for having more empirical data in
the molding industry than any other professional services firm in
North America as a result of coordinating the annual North American
We are deeply entrenched
Plastics Industry Study since 1995. Our plastics practice is co-led
in the plastics industry
by Jeff Mengel and Ted Morgan. We are deeply entrenched in the
and regularly participate
plastics industry and regularly participate as presenters at industry
as presenters in industry
organizations and events, such as the Plastics News Executive Forum,
the Society of Plastics Engineers, the Manufacturers Association for
organizations and events.
Plastics Processors (MAPP), and the Society of Plastics Industry.
In addition, members of the Plante Moran plastics team have been featured authors in
industry publications such as Plastics News, Modern Plastics, Injection World magazine,
MoldMaking magazine, Plastics Technologies, and Automotive News.
We utilize the data we collect and our entrenchment in the plastics industry to support more
than 200 clients annually. Services include:
Operational Effectiveness
Strategy Consulting
Technology
Due Diligence
++ Controls
++ Infrastructure
++ Implementation
International Advisory
Cost Modeling and Quote
Templates
++ Financial
++ Strategic
++ Operational
++ Technology
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Strategy
Consulting
Operational
Effectiveness
International
Advisory
Our Services.
Due Diligence
Technology
Financial
Controls
Strategic
Infrastructure
Operational
Implementation
Technology
21
In Closing
Successful companies have a strong value proposition and often support their value
proposition with quoting discipline. Companies that misfire often have high manufacturing
complexity (number of presses, molds, and resins to monitor and schedule) and misaligned
organizational structures. You can impact your enterprise value
today by taking a holistic approach to looking at your business,
We are here to help
surrounding yourself with talent that can keep up with todays pace
you create and
of change, and becoming an adaptive and innovative enterprise.
execute your plan.
We provide a number of materials on our website (http://plastics.
plantemoran.com) to help you assess your organizations level of financial stress and
develop your strategy. Embracing the challenges facing you with a plan is half the battle.
We are here to help you create and execute your plan should you need it.
Jeff Mengel
Ted Morgan
22
23
Benchmarking Data
Strategy
Operational Data
24
Snapshots
-- Percent Utilization
-- Average Time for Setup
-- Average Number of Setups per Week
++ Descriptive Press Statistics
Profile/Tube/Pipe Extrusion
-- Number of Lines
-- Average Age of Lines
-- Percent of Lines with Down-line
Automation
-- Percent of Lines
Co- or Tri-extruded
-- Percent of Lines with Crosshead
Extrusion
-- Percent Utilization
-- Average Time for Setup
-- Average Time of Setups per Week
++ Shift Activity
++ Tooling Attributes
-- Classification of
Mold Type
-- Source of New Obtained
++ Resin Usage and Consumption
++ Complexity Calculation
Financial Performance
25