Saltillo

A standardized startup format was updated to verify and control mold temperature zones prior to production startup, ensuring proper thermal conditions and preventing out-of-spec parts during machine warm-up.

Before this improvement, insufficient temperature control during startup could result in up to four hours of unstable production, generating nonconforming parts until the process reached thermal equilibrium. This condition typically occurred during Monday shift startups.

By implementing the updated temperature verification format, the following measurable benefit was achieved:

Prevention of approximately 240 nonconforming parts per startup, equivalent to $720 USD per event.

Avoidance of scrap during 49 weekly startups per year, generating an estimated annual savings of $35,280 USD.

This Kaizen initiative significantly improved process stability during startup, reduced scrap generation, and ensured consistent product quality, while delivering a conservative estimated annual savings of $35,280 USD.