Problem explained
Cooling timers may hold molds shut after the parts are solid, which slows every cycle.
How it works today
The plant makes plastic parts on 26 injection presses, which melt plastic and shoot it into a steel mold.
In each cycle, from mold closed to part out, a cooling timer keeps the mold shut while the part hardens.
A timer set with a safety margin keeps the mold shut after the part is already solid.
What we saw and heard
- On our visit all seven cooling timers we could read were round numbers, a sign they were set by habit.
- On our visit we were told a timer is set "safe" when a job starts, then left if parts are good.
- We did not see a timer shortened, so the spare time in each one is our estimate.
What it costs
- On the five longest-running jobs, one second less per cycle frees about 600 press hours per year, worth about $23,100.
- We assume orders fill 70 percent of the freed hours, and each filled hour earns $55.
Illustrative sample. The plant, the walk and the footage are synthetic. Figures from our analysis are estimates made with AI, not guarantees.