Pythia Industries

Sample Plant

Premises

One person at each press
  • One person stands at each of three presses for about 2,500 hours per year.
  • We counted three presses on one visit, and the job log gives the hours.
  • If this is wrong: fewer presses or shorter jobs, and the figure falls with them.
  • Each such press is worth about $18,500 per year by our figures.
Hand work against the cycle
  • The hand work of two presses fits inside one cycle.
  • We saw each person wait between parts, and we did not time it.
  • If this is wrong: one person cannot keep up with two presses, and only a way that removes the cutting applies.
  • The first check settles it in an hour.
Where the freed hours go
  • The freed hours come out of overtime, or a hire is not made.
  • Payroll shows about 180 overtime hours per week.
  • If this is wrong: the same people work the same hours, and no cash is saved.
Neighboring presses, same hours
  • Two presses on long jobs stand side by side and run the same hours.
  • The two large presses we saw stand side by side.
  • The small press had no such neighbor on the film.
  • If this is wrong: the long jobs are scheduled onto neighboring presses first, which costs mold changes and planning time.

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