Study a Startup Scrap Spike Before Standardizing the Fix
Use a PDSA cycle to investigate startup yield loss after a changeover.
startup yield Line 6 scrapped 180 units after changeover. The team has one run tomorrow to learn before the weekly schedule gets tight. The danger is changing three settings and declaring victory without knowing what worked. PDSA Plan -> Do -> Study -> Act Treat the next startup as a learning cycle: prediction, small test, evidence, decision. Tweak and hope Change the settings, watch the scrap bin, argue later. A fix becomes knowledge, not folklore. Quality loss after startup needs learning discipline before standard work changes. P Prediction D Test A Decision state the theory Operations believes seal-jaw warmup is…
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