Illustrative sample. The plant, the weeks and the footage are synthetic.

Pythia Industries
Sample Plant
Back to the week 3 report

Going well

Set up a mold-maintenance program

This week

  1. Past stop and scrap records are being matched to the mold behind each one, to find the molds that stop presses most. A quarter are matched so far.

  2. The ERP already logs every stop and batch of scrap, so the first records were pulled the day it was approved.

  3. We read past stop, scrap and job records in the ERP, which show the mold in each press at the time. A quarter of the 1,640 records from the last six months are already matched.

  4. No fewer stops yet, while past records are matched to molds to find the worst ones.

  5. Keep matching records every day until each one has its mold.

    Who owns it: Tool room lead (Ray Okafor)

Week by week

  1. Week 1
  2. Week 2
  3. Week 3
  4. Week 4
  5. Week 5
  6. Week 6
  7. Week 7
  8. Week 8

Approved

41 days ago

Going well

4 of 6 weeks

Worth

$55K / yr

  1. Week 3Approved
  2. Week 3This reportPast stop and scrap records are being matched to the mold behind each one, to find the molds that stop presses most.
  3. Week 4Matching past records to molds stalled, with nothing matched on any day this week.
  4. Week 5Every stop and scrap record now has its mold, and a small group of molds caused most stops and bad parts from wear.
  5. Week 6Most of the worst molds now carry a counter, and each count goes straight to that mold's record in the ERP.
  6. Week 7All the worst molds now carry counters, and each gets a quick check before every day shift.
  7. Week 8The daily mold check was skipped three days in a row this week.

Improvement: Set up a mold-maintenance program