Implementation plan
1. List scrap by mold, weigh bins
The list names the molds, and the bins show whether they still make the scrap.
| Action | - List last month's scrap by mold from the ERP, 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.
|
| Owner | A process technician |
| Purchases | None |
| Decision | Do the same few molds lead the list and fill their bins, with flaws that change from part to part? |
| Fallback | If every part has its flaw in the same place, that mold goes to the mold shop first. |
2. Test settings on the worst molds
Test runs find the settings at which each mold makes good parts.
| Action | - Take one mold at a time, in its usual press, with its usual plastic.
- Change one setting at a time, such as fill speed, pressure or cooling time.
- Weigh and check the parts of each run, and note where they start to go bad.
- Choose the settings in the middle of the range where parts stay good.
- Where a customer has approved a part's settings, get their sign-off before using new ones.
|
| Owner | A process technician |
| Purchases | None. About 72 technician hours and 1,200 lb of test parts, about $5,800 in all. |
| Decision | Does the mold make good parts across a range of settings, not just at one point? |
| Fallback | If there is no such range, the mold or the plastic is the cause, and tests on that mold stop. |
3. One signed sheet at each press
Every shift starts from the same settings, and each change carries a name.
| Action | - Write the chosen settings on one sheet and post it at the press.
- Every shift starts the job from the sheet.
- Any change is written on the sheet with a name, the time and the reason.
- The technician reads the changes every week, and adds a change to the sheet if it works.
- Weigh the rejected parts of these molds every week for a month.
|
| Owner | A process technician, with each shift's supervisor |
| Purchases | None |
| Decision | Does the weighed scrap on these molds fall, and stay down for a month? |
| Fallback | If the scrap returns on one shift, that shift starts its next run with the technician at the press. |
Illustrative sample. The plant, the walk and the footage are synthetic. Figures from our analysis are estimates made with AI, not guarantees.