Risks
A timer is cut too far
| Risk | A part that comes out too warm can look right at the press, then bend or shrink as it cools. |
| Early sign | Parts pass at the press but fail at assembly or at the customer. |
| Mitigation | Check every step by measuring cold parts, and stop one second before the first failure. |
| Impact | A customer return, and that job trialed again. |
A shift raises the timer again
| Risk | A shift that meets a defect adds cooling time to be safe, and nobody takes it off again. |
| Early sign | The timer on the screen is above the time on the job's settings sheet. |
| Mitigation | The sheet holds the tested time, and any change to it is written down with its reason. |
| Impact | That job's share of the saving, about $4,600 per year. |
A customer's approval takes weeks
| Risk | On a part whose process a customer approved, the shorter cycle cannot ship until the customer signs it off. |
| Early sign | A tested job still runs at its old timer while the request is out. |
| Mitigation | Trial the jobs that need no approval first, and send the other requests together. |
| Impact | The saving on those jobs arrives weeks later. |
Illustrative sample. The plant, the walk and the footage are synthetic. Figures from our analysis are estimates made with AI, not guarantees.