The Cost of Not Having a Central Handling System

Let’s look at the ramifications of not having a central system – and think about the associated costs – can you estimate your yearly losses from these problems?

It is not unusual to discover tens of thousands – even hundreds of thousands of wasted dollars in a plant without a good centralized resin handling system.

PROBLEMS = LOST PRODUCTION TIME, LOST PROFITS AND LOST CUSTOMERS!

Problems Experienced Without a Central System:

• Space needed for plant consolidation
  - If you can’t handle more process machines some other plant will
   
• Congestion on the floor around machines
  - Slows workers – increases spillage and chance of injury
   
• Lack of material validation/verification
  - Can’t bid on contracts where validation required
   
• Wrong material going to wrong machine
  - Lost production time, rejects and lost material
   
• High material spillage
  - Loss of material and labor + safety hazard
   
• Material related part defects
  - Producing scrap instead of saleable parts
   
• High maintenance/labor costs
  - Increased payroll and parts cost
   
• Frequent material changes
  - Lost production time
   
• Inefficient work flow
  - Wastes space and labor
   
• Lack of Automation
  - Adds labor costs and extends lead times
   
• Constrained production capacity
  - Can’t increase revenue
   
• Lengthy hopper cleanout times
  - Increased labor - lost production
   
• Poor drying of material
  - Rejected parts – lost customers

Usually, the cost to install or upgrade an efficient resin handling system is recovered in a matter of months – not years – See examples of central system paybacks. Investment payback in Months – Not Years but a review of conditions in your plant is required to identify areas of loss and possible remedies.