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Our scrap rate went from 8% to under 1% in six months
Six months ago, our shop floor was a mess with bad parts. We were scrapping about 8% of our aluminum runs on the old Haas. The big change was when our lead programmer started putting a 5-minute tool check and offset routine at the start of EVERY shift. He made it a rule, no exceptions. Now we're under 1% scrap and the boss is actually smiling. Has anyone else seen a huge drop just from sticking to a simple daily check?
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the_jesse6mo ago
We did the same with coolant checks and our rework rate fell off a cliff, lol.
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corar786mo ago
Exactly! It's wild how one small step can catch so many problems early. We started logging every check and found most failures came from the same two issues everyone was skipping. Now it's just part of the routine, like checking your oil. Saves a ton of time arguing about who messed up later.
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mary8363mo ago
Read a case study from a manufacturing group once that found the same thing (I think it was on assembly line stuff). Their defect rate dropped like 40% just from making everyone do a quick fluid level check before the next step.
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