THE REPAIRERS’ BAND
LET’S DESTROY THE DAMNED REJECTS!
I’d like to talk about an always underestimated problem.
The Cost of the Damned Rejects.
To do that I’ll tell you what has just happened.
When I talk about rejects, maybe you think about a complaining client. The material coming back again for reworking. Maybe you think you have to give a discount.
But the situation is worse than you can imagine.
You never think that everything can fall to pieces. Instead you never know how you could fall to the bottom.
Here’s what happened to me.
Yesterday I visited a machine working company.
While I was getting out of the car.
I collected my things, I opened the door and saw…
A van with 3 workers on board.
An Italian and 2 Pakistanis.
The van had a big sign on the side “Foundry xxxxxx”
At first I thought: “Every time I call this foundry, they tell me that they don’t need my machines”
Immediately afterwards: “But what are 3 workers doing here? The foundry is 200 km far from here!!”
They left the van and put on a tool belt. From their bag I clearly recognised deburring tools.
We went together inside the machine working company and I asked for my company’s contact person for some explanations.
He explained that the foundry is one of their suppliers and that the three workers had to repair a lot of pieces that had not been deburred correctly.
The surfaces required a certain number of operations (hole openings and deburring…) the foundry had forgotten some of those operations, for this reason “the repairers’ band” was there to check and to fix all the pieces.
They had to check the one by one, thousands of pieces!
A DRAMATIC situation!
Dramatic and embarrassing for everyone! For the foundry that was paying a lot of money, for the company that processed the production and had to resell the pieces that delayed the delivery.
Cost, costs, costs!
An announced catastrophe.
If you produce a piece and then you give it out for cutting, the deburring is controlled by a team of workers, how can you think you don’t have a problem?
I want to be frank, it is useless to have the ISO 9001 certification, if you deburr the pieces by hand!
It’s the truth, and it’s useless to hide behind a finger.
If you work in the automotive sector, perhaps you guarantee that you will not deliver more than 3 reject pieces per thousand pieces.
If you have the machines making the product and check it, well it’s possible. If you do some operations by hand, then it’s IMPOSSIBLE.
But there is a solution!
You’ve to install a cutting and deburring machine which will make you a reliable, repeatable and certifiable process!
One of my machines allows you to:
- – deburr all the pieces in the same way
- perform all operations without forgetting anything
- carry out checks during the cycle
and in addition
- have a correct cycle time
- know exactly what the piece costs
- be independent of your workers’ capacity
- have a sure and constant productivity
- break down labour costs
increase safety in your factory
So, why can’t you automize your cutting and deburring process?
Don’t hide behind the usual excuses.
They are always the same:
1. it isn’t profitable, it cost less by hand.
2. I don’t have the quantity to automize the process
3. but we are a small company, nobody in our company has the skills to use such machines
4. I’ve no space
My external supplier costs nothing
All unnecessary excuses, which make you lose time and money.
How often have I heard these excuses.
I understand that you have to be courageous to invest, but if you wait continually you fall into the abyss.
If you just consider the cost of the deburring labour, it happens many times that it isn’t convenient to automate.
But if you consider the unexpected costs (such as the bloody rejects) then you realize that you can invest a lot of money.
Automizing your deburring process allows you to make a leap into the future.
Download the video showing you how I automized a simple deburring operation, an operation that wasn’t worth automation.