List last month's scrap by mold from the ERP, the plant's job and stock system, and by shift where it is recorded.
At the start of a shift, empty the scrap bins of the three molds highest on the list that are running, and of one other press.
At the end of the shift, weigh the rejected parts in each bin on the floor scale.
Note whether every rejected part has its flaw in the same place.
Cost
About $160 of a process technician's time: about three hours at $52 per hour. The list comes from the ERP and the bins are weighed on the plant's own floor scale, so nothing is bought.
Duration
About an hour for the list, then one shift for the bins
Confirmed if
A few molds lead the list, and their bins hold several times the rejected parts of the other bin. Settings are the likely cause if the scrap changes from shift to shift, or the flaw changes from part to part.
Ruled out if
Last month's scrap is spread across many molds, and the three bins hold about as much as the other one.
Settings are also not the cause if every rejected part has the same flaw in the same place on every shift.