Risks
One person cannot keep up with two presses
| Risk | On a part with more cutting, parts pile up at the table and the belt stands stopped while the press keeps running. |
| Early sign | The belt is stopped with a full table more than a few times per shift. |
| Mitigation | Time the hand work first, and pair only presses whose hand work fits inside one cycle. |
| Impact | The saving at that pair, about $36,900 per year. |
The freed hours stay on the payroll
| Risk | The second person stays near the pair, or overtime is worked as before, so nothing is saved in cash. |
| Early sign | Overtime hours per week do not fall after the first pair is fitted. |
| Mitigation | Name the work the freed person moves to before the belts are bought. |
| Impact | All of the saving: the freed hours stay operator time. |
A bad part reaches the box unseen
| Risk | One person now looks at the parts of two presses, and a bad part is easier to miss. |
| Early sign | More parts from these two jobs are rejected at the final check or by a customer. |
| Mitigation | Keep the look at each part inside the hand work that is timed, and check the first box of each shift. |
| Impact | Rejected parts and a customer complaint, which can outweigh the hours saved. |
Illustrative sample. The plant, the walk and the footage are synthetic.