Pythia Industries

Sample Plant

Risks

The cart is loaded after the press stops

RiskIf the next job is not known in time, the cart is loaded during the change and no minutes move out of the stop.
Early signA press stands open while someone is away from it, fetching.
MitigationThe shift supervisor names the mold changes due at the start of each shift.
ImpactThe price of the carts, about $9,000, with no minutes saved.

One shift goes back to the old way

RiskThe carts are used for some weeks, then skipped on a busy shift, and the waiting comes back.
Early signThe job log's median change on one shift rises back toward 63 minutes.
MitigationOne named person per shift for the carts, and the change times read by shift each week.
ImpactUp to about $20,300 per year, if every shift goes back.

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