Risks
The mold, not the settings, makes the scrap
| Risk | A worn or damaged mold makes bad parts at any settings, so the test runs find no range where parts stay good. |
| Early sign | Rejected parts have the same flaw in the same place, on every shift. |
| Mitigation | Sort the rejected parts in the first check, and send such a mold to the mold shop before any test. |
| Impact | The cost of testing that mold, about $1,900. |
A shift goes back to its own settings
| Risk | The sheet hangs at the press, but a shift starts the job from the numbers it remembers. |
| Early sign | Changes with no name appear on the sheet, or the bin fills faster on one shift. |
| Mitigation | One technician reads the changes on each sheet every week. |
| Impact | That mold's share of about $29,800 per year. |
A customer has to approve a changed setting
| Risk | Some customers approve the settings a part is made with. A change then waits for their sign-off, which can take four to twelve weeks. |
| Early sign | The test runs find settings that work, but the job still runs at the old ones. |
| Mitigation | Check which parts need a customer's approval before testing, and start with those that need none. |
| Impact | The saving on that part until the customer signs off. |
Illustrative sample. The plant, the walk and the footage are synthetic. Figures from our analysis are estimates made with AI, not guarantees.