Factory map

Press OEE

~53%of scheduled press time makes good parts

The rest goes to changeovers, breakdowns, and slow cycles. The fixes reach about 60%, roughly 13% more good parts from the same 26 presses. Freed hours pay only if sales fill them.

The material's pathThe selected zoneIdle presses & dead toolingParts waiting (WIP)Walled room (tool room, QC)

The selected zone

What feeds it, what it feeds, and what it is worth.

Fed by

The pressesStep 2 of 5

Molding floor

$467Kin improvements

Feeds

The problem

Every part runs through the presses, and they lose hours every day.

About 26 machines do all the molding, but they run on operator judgment rather than measured process settings, with slow changeovers, breakdowns, and cycle times padded past what the part needs. Recovering that time and steadying the process is capacity you already own, with no new press.

What it's worth

Total

$466K

Per year

$466K/yr

One-time

$0K

What to do

Put simple run tracking on every press, then go after the biggest loss first, whether that is changeover, downtime, or scrap.

Recover hidden press capacity$120K Take the padding out of the cycle$72K Cut changeover time with SMED$54K Cut scrap with scientific molding$120K Preventive maintenance on the presses$62K Swap to all-electric as presses retire$38K

The proof

Production counts live on a clipboard and a whiteboard, and nobody can state last week's uptime without digging
Cool timers are set with round-number padding to be safe and never trimmed with data
Operators walk back and forth for tools while the press sits stopped during a mold change