Problem explained
Small molds run in large presses that large jobs need, and use more electricity there.
How it works today
The plant makes plastic parts on 26 injection presses, which melt plastic and shoot it into a steel mold.
In twelve months, the job log shows about 60 runs of small molds in large presses, about 1,000 press hours.
We estimate 300 of those hours could move to a smaller press, which must be idle when the job starts.
What we saw and heard
- On our visit we saw a small mold running in a large press while two smaller presses stood idle.
- We did not see a large job waiting for that press.
What it costs
- We assume orders fill 70 percent of the freed hours, and each filled hour is worth about $55.
- With the extra electricity, small molds in large presses cost about $11,900 per year.
- Fixing it could save about $8,900 per year, after the staff time the fix takes.