Problem explained
The press stops first, then waits while its next mold, hoses and tools are fetched.
How it works today
The plant molds plastic parts to order: a press melts plastic and shoots it into a steel mold.
Each job runs in its own mold, with its own water hoses to cool it and tools to fit it.
The plant's job log shows about 2,200 mold changes per year, and half take longer than 63 minutes.
We estimate 15 minutes of each change is waiting, about 550 press hours per year.
What we saw and heard
- On our visit we saw a press stand open while its next mold came from the rack.
- We saw one person leave that press three times for hoses and tools.
What it costs
The waiting costs about $21,200 per year, if orders fill 70 percent of the lost press hours.
Illustrative sample. The plant, the walk and the footage are synthetic. Figures from our analysis are estimates made with AI, not guarantees.