The challenge
A Cadillac fuse panel would not mold flat. After a week of trials with the process engineer, a large number of parts had been scrapped.
The fix
A retired part-time worker at the plant offered an unconventional suggestion. Bob and the process engineer tried it, and it worked.
The result
The part molded flat and scrap stopped. Bob recommended a reward for the person whose idea solved it, and the CEO approved it.
The lesson
Good ideas come from anywhere on the floor. Test them on their reasoning, not on who suggested them.
Production Efficiency Consulting
Dealing with something similar?
Cycle time, scrap, mold downtime and bottlenecks on tools that are already running.