Calculation
| Summary | - Avoiding five of the nine stops per week, over 50 working weeks, is 250 stops per year.
- Each one loses about 1.2 hours of press time and 25 pounds of plastic.
- A freed press hour is counted at $38.50: $55 when an order fills it, which we assume for 70 percent of them.
- With plastic at $1.50 per pound, those stops cost about $20,900 per year today.
- Planned cleaning costs about $7,200 per year of mold shop time, which leaves about $13,700.
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| Unplanned stops avoided per year | 5 per week x 50 weeks = 250 |
| Press hours no longer lost | 250 stops x 1.2 hours = 300 |
| What those press hours are worth | 300 hours x $55 x 70 percent filled by orders = $11,550 |
| Plastic no longer scrapped at stops | 250 stops x 25 lb x $1.50 per lb = $9,375 |
| Less planned cleaning in the mold shop | 3 hours per week x 50 weeks x $48 per hour = $7,200 |
| What fixing it could save per year | $11,550 + $9,375 - $7,200 = $13,725 |
Not counted
- The time of the people who clear each stop is not counted.
- It is cash only if overtime falls, and payroll shows about 180 overtime hours per week.
- Planned cleaning is charged in full, with nothing taken off for the repairs it replaces.
- Repair parts, rush orders for parts and damage when a press closes on a stuck part are not counted.
- Orders that ship late because of a stop are not counted.
- Scrap that comes from press settings is another problem on this page, and is not counted here.
Illustrative sample. The plant, the walk and the footage are synthetic.