Pythia Industries

Sample Plant

Risks

A timer is cut too far

RiskA part pushed out too warm can look right at the press and bend or shrink out of size as it cools.
Early signParts pass at the press and fail at assembly, or at the customer.
MitigationCheck every step on cold parts, by measurement, and stop one second before the first failure.
ImpactA customer return, and that job trialed again.

A shift raises the timer again

RiskA shift that meets a defect adds cooling time to be safe, and nobody takes it off again.
Early signThe timer on the screen is above the time on the job's settings sheet.
MitigationThe sheet holds the tested time, and a change to it is written down with its reason.
ImpactThat job's part of the figure, about $4,600 per year.

A customer's approval takes long

RiskOn a part whose process a customer approved, the shorter cycle cannot ship until the customer signs it off.
Early signA tested job still runs at its old timer because the request is out.
MitigationTrial the jobs that need no approval first, and send the other requests together.
ImpactThe saving on those jobs arrives weeks later.

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