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

Pythia Industries
Sample Plant
Back to the week 4 report

To improve

Set up a mold-maintenance program

This week

  1. Matching past records to molds stalled, with nothing matched on any day this week. The molds that stop presses most cannot be named until it is done.

  2. No fewer stops yet, and the worst molds cannot be named while the matching is stuck.

    Since last week: Last week the matching moved quickly, and since then it has stopped completely.

  3. We checked the ERP each workday for stop and scrap records matched to a mold. None were matched all week, so the worst molds still cannot be named.

  4. The matching likely has no set time in the tool room's day, so urgent mold repairs came first.

  5. Give the matching a set time in the tool room's day so it moves every day.

    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 3Past stop and scrap records are being matched to the mold behind each one, to find the molds that stop presses most.
  3. Week 4This reportMatching 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