Premises

Settings as the cause	The scrap on these molds comes from the settings, not from the molds themselves. We saw settings sheets changed by hand at two presses with full scrap bins. We did not see why any part was scrapped. If this is wrong: the rejected parts carry the same mark in the same place on every shift, and the mold shop has to repair the mold.
Share of scrap removed	Trials and one sheet take about 0.4 percent of the plant's resin out of the scrap. That is about 21 percent of what the six molds scrap. Published cases report more, on molds with sensors. If this is wrong: weighed scrap on the molds studied falls by less, and the figure falls with it.
One sheet on every shift	Every shift starts the job from the same sheet. The saving lasts only while the sheet is used. If this is wrong: changes with no name return to the sheets, and so does the scrap.
Cost of a scrapped pound	The press time and labor in a scrapped pound add about 20 percent to its resin. The resin is cash. The press time and labor are cash only if orders fill those hours or overtime falls, and payroll shows about 180 overtime hours per week. If this is wrong: count the resin alone, about $30,000 per year before the technician's time.