Run a PDCA improvement cycle on a recurring makeready waste problem.
Monday first-job makeready averages 450 extra sheets above the normal setup allowance. PDCA: Plan -> Do -> Check -> Act The common trap is installing a permanent fix after one theory, then never checking whether waste changed or another problem appeared. Plan Problem: Monday first-job spoilage averages 450 extra sheets. Target: reduce to 325 or less. Hypothesis: weekend washup leaves setup conditions inconsistent. A plan needs a measurable target and a theory that can be tested. Do Test a pre-shift fountain solution check and ink key preset on the next three Monday first jobs only. The test is small enough…
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