Risks
A timer is cut too far
| Risk | A part pushed out too warm can look right at the press and bend or shrink out of size as it cools. |
| Early sign | Parts pass at the press and fail at assembly, or at the customer. |
| Mitigation | Check every step on cold parts, by measurement, and stop one second before the first failure. |
| Impact | A customer return, and that job trialed again. |
A shift raises the timer again
| Risk | A shift that meets a defect adds cooling time to be safe, and nobody takes it off again. |
| Early sign | The timer on the screen is above the time on the job's settings sheet. |
| Mitigation | The sheet holds the tested time, and a change to it is written down with its reason. |
| Impact | That job's part of the figure, about $4,600 per year. |
A customer's approval takes long
| Risk | On a part whose process a customer approved, the shorter cycle cannot ship until the customer signs it off. |
| Early sign | A tested job still runs at its old timer because the request is out. |
| Mitigation | Trial the jobs that need no approval first, and send the other requests together. |
| Impact | The saving on those jobs arrives weeks later. |
Illustrative sample. The plant, the walk and the footage are synthetic.