Pythia Industries

Sample Plant

Risks

The walk is done once and not repeated

RiskThe first walk fixes the largest leaks, and then no date is set for the next. New leaks open as hoses and couplings wear.
Early signA quarter passes with no new tag on a leak, and the pumping minutes at a meal break creep up.
MitigationOne named person, a date each quarter, and every reading on one sheet.
ImpactAbout $6,400 per year: what the leaks add to the figure.

A press starves for air after the setting comes down

RiskPressure 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 signOn the day of a step, parts stick in the mold at one press, or a moving part of its mold slows down.
MitigationSteps of two psi, a full shift between them, and the farthest press watched each time.
ImpactSlower cycles or rejected parts at that press until the setting goes back up.

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