Risks
The counters are fitted but nobody reads them
| Risk | A count that passes the one on its card with no cleaning changes nothing. The mold runs until it fails, as before. |
| Early sign | A mold on the rack shows a count past the one on its card. |
| Mitigation | One named person reads the counter at every mold change and signs the log. |
| Impact | The whole figure, about $13,700 per year. |
The mold shop has no time to clean between jobs
| Risk | Repairs after failures come first, so planned cleaning is skipped in a busy week. |
| Early sign | Molds go from a press to the rack without a stop at the bench. |
| Mitigation | Hold about 3 hours per week in the mold shop for these molds before other work is planned. |
| Impact | The stops return, and the counters only record them. |
Illustrative sample. The plant, the walk and the footage are synthetic.