Evidence
Read together, full bins, hand-changed sheets and the scrap record suggest each shift runs a few molds its own way.
On our visit
Scrap bins at three presses
04:10, 09:10 and 16:30At three presses the scrap bin was over half full of rejected parts. Other bins held far less.
Checked by eye on a frame of our video
Settings sheets changed by hand
09:25 and 16:45Two of those presses had settings sheets changed by hand. Settings may differ from shift to shift.
Checked by eye on a frame of our video
Plant records
Scrap by mold
Six of about 140 molds make 38 percent of all the plant's scrap.
The ERP scrap record, twelve months
The plant's scrap rate
About 5 percent of the plastic issued to the presses did not ship as good parts.
The ERP scrap record, twelve months