Pythia Industries

Sample Plant

Risks

One person cannot keep up with two presses

RiskOn a part with more cutting, parts pile up at the table and the belt stands stopped while the press keeps running.
Early signThe belt is stopped with a full table more than a few times per shift.
MitigationTime the hand work first, and pair only presses whose hand work fits inside one cycle.
ImpactThe saving at that pair, about $36,900 per year.

The freed hours stay on the payroll

RiskThe second person stays near the pair, or overtime is worked as before, so nothing is saved in cash.
Early signOvertime hours per week do not fall after the first pair is fitted.
MitigationName the work the freed person moves to before the belts are bought.
ImpactAll of the saving: the freed hours stay operator time.

A bad part reaches the box unseen

RiskOne person now looks at the parts of two presses, and a bad part is easier to miss.
Early signMore parts from these two jobs are rejected at the final check or by a customer.
MitigationKeep the look at each part inside the hand work that is timed, and check the first box of each shift.
ImpactRejected parts and a customer complaint, which can outweigh the hours saved.

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