🇦🇺Australia
Capacity Loss from Rework
2 verified sources
Definition
Batch variability, color instability, and defects halt lines for adjustments and re-runs.
Key Findings
- Financial Impact: AUD 15,000-60,000/year (40 hours/month downtime at AUD 100/hour machine rate)
- Frequency: Weekly during multi-color production
- Root Cause: Poor heat resistance, inconsistent raw materials, and manual mixing errors
Why This Matters
The Pitch: Australian plastics firms lose AUD 40 hours/month in idle time from color failures. Digital matching restores full capacity.
Affected Stakeholders
Operations Director, Machine Operator, Maintenance
Deep Analysis (Premium)
Financial Impact
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Current Workarounds
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Methodology & Sources
Data collected via OSINT from regulatory filings, industry audits, and verified case studies.
Related Business Risks
Cost of Poor Quality
AUD 20,000-100,000/year in material waste and rework (2-5% of production costs for mid-sized firm)
Waste from Trial-and-Error
AUD 10,000-50,000/year in scrapped materials and labor (1-3% of material costs)
PPAP-Bottlenecks und Freigabe-Verzögerungen
Logikbasiert: ca. AUD 50.000–150.000 entgangener Umsatz pro Jahr durch 1–2 Monate verspätete Serienfreigaben infolge unvollständiger/fehlerhafter PPAP-Sets; zusätzlich ca. 40–80 Maschinenstunden/Jahr ungenutzte Kapazität pro kritischem Projekt.
Überhöhte PPAP-Bearbeitungskosten und Doppelarbeit
Logikbasiert: ca. 400–1.000 zusätzliche Arbeitsstunden pro Jahr für manuelle PPAP-Dokumentation und Nacharbeit, entsprechend rund AUD 20.000–60.000 Personalkosten p.a. in einem typischen mittelgroßen Kunststoffwerk mit PPAP-pflichtigen Kunden.
Kundenabwanderung durch nicht bestandene oder verspätete PPAPs
Logikbasiert: ca. 5–15 % des PPAP-pflichtigen Jahresumsatzes gefährdet; bei einem typischen Umsatz von AUD 4 Mio. mit Automotive- und ähnlichen Kunden entspricht das ca. AUD 200.000–600.000 potenziell verlorenem oder nicht gewonnenem Umsatz pro Jahr.
Capacity Loss from Manual Kanban Bottlenecks
AUD 20,000-100,000/year in lost capacity (2-5% of production value for mid-size firm, based on industry benchmarks for idle time)
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