Problem explained
The press stops first, and only then are the next mold, hoses and tools fetched.
How it works today
The plant molds plastic parts to order, and each job runs in its own steel mold inside a press.
When a job ends the press stops, and it makes no parts while the next mold, hoses and tools are fetched.
We estimate 15 minutes of waiting per change, about 550 press hours per year.
What we saw
- On the visit we saw a press stand open while its next mold came from the rack.
- We saw one person leave that press three times for hoses and tools.
- We did not see a whole change: the job log shows about 2,200 per year, half of them longer than 63 minutes.
What it costs
- If orders fill 70 percent of those hours, the waiting costs about $21,200 per year.
- Fixing it could save about $20,300 per year, once about $900 of yearly upkeep is paid.