Pythia Industries

Sample Plant

Risks

The counters are fitted but nobody reads them

RiskA count that passes the one on its card with no cleaning changes nothing. The mold runs until it fails, as before.
Early signA mold on the rack shows a count past the one on its card.
MitigationOne named person reads the counter at every mold change and signs the log.
ImpactThe whole figure, about $13,700 per year.

The mold shop has no time to clean between jobs

RiskRepairs after failures come first, so planned cleaning is skipped in a busy week.
Early signMolds go from a press to the rack without a stop at the bench.
MitigationHold about 3 hours per week in the mold shop for these molds before other work is planned.
ImpactThe stops return, and the counters only record them.

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