Evidence
Read together, our visit and the job log show small molds in large presses all year, though they fit smaller ones.
On our visit
Small mold in a large press
11:05A small mold ran in a large press, though the job log shows it has run in a smaller one.
Checked by eye on a frame of our video
How a job gets its press
11:25 to 11:34Plant staff said a job goes in whichever press is idle, so a small mold can end up in a large one.
Said by plant staff during our visit
Smaller presses standing idle
16:30Two smaller presses stood idle in the same hour. One is the size the small mold has run in.
Counted by eye on frames of our video
Plant records
Small molds on the large presses
About 60 runs on large presses in twelve months used molds that also ran two sizes smaller.
The ERP job log, twelve months
Mold records without a press size
No mold's record names its smallest press, so the scheduler has no press to try first.
The ERP mold records
Orders shipped late
About one order in seven shipped late, so orders do wait for presses and could fill freed hours.
The ERP's shipping record, twelve months