They Just Don't Get It!

Operators initially resisted time tracking, causing tension. Greg chose culture over short-term output, sacrificing an hour of production to implement metrics. Data revealed a press issue ignored for weeks by management, leading to repairs and new calibration schedules. Operators saw data as a voice, not punishment. The Matrix Moment Flaviu describes early analytics as overwhelming “numbers and numbers” until he could “see the code.” Translating data into clear visual dashboards allowed managers to quickly spot issues and make decisions, transforming raw data into actionable insights. Elephant Hunting: The 40% Swing “Elephant hunting” found major losses in setup times, operating at 70-80% efficiency. Improvements pushed them beyond 100% to 120% efficiency—a 40% swing. Last month alone, they saved 172 setup hours and 500 overall labor hours, equivalent to three to four jobs eliminated through natural attrition. The Underdog Champion

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