How many drums went out short, and who found out first?

A customer orders a length. The drum that reaches him is a metre or two short, or ten.

Length is measured by a counter, and counters drift. Nobody records measured against ordered per drum, so shortages are discovered by the customer rather than at dispatch.

Measured length is recorded per drum against the order, and a drum below tolerance cannot be dispatched.

Copper is the cost. Input weight and output weight are both known and rarely compared closely enough to act on.

A drawing line that has drifted, or a die worn past its life, loses a fraction of a percent that is invisible monthly and enormous annually.

Weight in and weight out are recorded at every process, so a drifting line is visible in weeks.

Extrusion lines stop for material changes, breaks, screen changes and faults. Every stop wastes material at start-up as well as time.

Stops are known to the operator and to nobody else. The reason is rarely captured, so a recurring cause is never separated from an occasional one.

Each stop is logged against the line with a reason from your own list, on the same screen the operator already uses.