Evidence
Read together, the walk and the job log show presses waiting for things that could be ready before they stop.
On the walk
Press open, waiting for its mold
14:20 to 15:50A press stood stopped and open while its next mold came from the rack. It made no parts meanwhile.
Checked by us on a still of the film
Three trips for hoses and tools
14:30 to 15:45One person left the stopped press three times for hoses and tools. Nothing was set out beforehand.
Counted by us on stills of the film
Molds on racks in the mold shop
22:40Molds stood on racks in the mold shop, none set out for its next job. The next mold starts here.
Checked by us on a still of the film
Mold fetched after the stop
23:05 to 23:14Mold shop staff said the next mold is fetched when the press goes down. So each change waits.
Said by plant staff on the walk
Plant records
Mold changes in the job log
The job log shows 2,200 mold changes in a year. Half of them took longer than 63 minutes.
The ERP job log, twelve months
Changes on the busiest presses
Eight presses made about half of all mold changes. A fix fitted there reaches the most changes.
The ERP job log, twelve months