Evidence
Read together, the walk shows it happening, and the job log shows how often and that the molds fit elsewhere.
On the walk
Small mold in a large press
11:05We saw a small mold running in a large press. The job log shows it also runs in a smaller one.
Checked by us on a still of the film
How a job gets its press
11:25 to 11:34Staff said a job goes in whichever press has no job. So a small mold can land in a large press.
Said by plant staff on the walk
Smaller presses standing idle
16:30Two smaller presses stood with no mold in them. A small job had somewhere else to run that hour.
Counted by us on stills of the film
Plant records
Small molds on the large presses
In twelve months, about 60 runs on a large press used a mold that also ran two sizes smaller.
The ERP job log, twelve months
Mold records without a press size
A mold's record names no smallest press. So the schedule has nothing to try first.
The ERP mold records
Orders shipped late
About one order in seven shipped late. Orders wait for presses, so a freed hour can be filled.
The ERP's shipping record, twelve months