Risks
One person cannot keep up with two presses
| Risk | On a part that needs more trimming, parts pile up at the table while both presses keep running. |
| Early sign | Parts pile up on the table more than a few times per shift. |
| Mitigation | Time the work first, and pair only presses where one person has time for both. |
| Impact | The saving at that pair, about $36,900 per year. |
The freed hours stay on the payroll
| Risk | The second person stays near the pair, or overtime is worked as before, so no cash is saved. |
| Early sign | Overtime hours per week do not fall after the first pair is fitted. |
| Mitigation | Name the work the freed person moves to before the belts are bought. |
| Impact | The whole saving: the hours are freed but still paid for. |
A bad part reaches the box unseen
| Risk | One person now checks the parts of two presses, and a bad part is easier to miss. |
| Early sign | More parts from these two jobs are rejected at the final check or by a customer. |
| Mitigation | Include the check of each part in the timed work, and check the first box of each shift. |
| Impact | Rejected parts and a customer complaint, which can outweigh the hours saved. |
Illustrative sample. The plant, the walk and the footage are synthetic. Figures from our analysis are estimates made with AI, not guarantees.