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

Pythia Industries
Sample Plant
Back to the week 8 report

Urgent

Set up a mold-maintenance program

This week

  1. The daily mold check was skipped three days in a row this week. Most of the week's stops on the worst molds came on those days.

  2. Stops on the worst molds went back above the goal once the daily check was skipped.

    Since last week: Last week the check ran every day and stops fell, and this week it was skipped on most days and stops rose.

  3. We watched the day shift start on camera and read the ERP downtime log for the worst molds. Four of their five stops came on the three days the check was skipped.

  4. The check is likely not yet on the day shift's checklist, so nothing prompts it at the start of the shift.

  5. Put the mold check on the day shift's checklist, with a sign-off for each 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 3Past 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 8This reportThe daily mold check was skipped three days in a row this week.

Improvement: Set up a mold-maintenance program