Risks
The walk is done once and not repeated
| Risk | The first walk fixes the largest leaks, and then no date is set for the next. New leaks open as hoses and couplings wear. |
| Early sign | A quarter passes with no new tag on a leak, and the pumping minutes at a meal break creep up. |
| Mitigation | One named person, a date each quarter, and every reading on one sheet. |
| Impact | About $6,400 per year: what the leaks add to the figure. |
A press starves for air after the setting comes down
| Risk | Pressure is lost along the line, so the farthest press gets less than the compressor room sends. One step too many leaves that press short. |
| Early sign | On the day of a step, parts stick in the mold at one press, or a moving part of its mold slows down. |
| Mitigation | Steps of two psi, a full shift between them, and the farthest press watched each time. |
| Impact | Slower cycles or rejected parts at that press until the setting goes back up. |
Illustrative sample. The plant, the walk and the footage are synthetic.