A recent home DIY project that I undertook illustrates the need for metalcasters to have good firm control over their estimated vs. standard vs. actual costs. At the end of the day, a foundry either "wins" or "loses" by what happens on the foundry floor with regards to the P&L (Profit and Loss)
As an illustration, a simple toilet seat replacement project went horribly awry. I mean, replacing a toilet seat should be a simple task - unloosen the vinyl screws, and simply replace with a new one. Literally, no tools are required. However...
I estimated this project to take no more than five minutes. The toilet seat replacement had already been purchased and was just sitting there for me to carve out five minutes to replace. I had gotten tired of being reminded that the toilet seat needed replacing, so it became a #1 DEFCON FIVE priority to keep peace in the house. Peace and Harmony will Prevail!
However, when I went to loosen the screws, they were fastened too tight. Ok, I grabbed a wrench and a screw driver and attempted to "break it" apart. Nope, not going to happen. The brass screws were very fragile and corroded. After about twenty minutes of trying the "simple" things to solve the situation, I resorted to penetrating oil and left it alone. Already, I am fifteen minutes beyond my estimated time and at best the standard time would have been no more than ten minutes.
However, I came back to the project after allowing time for the penetrating oil to do it's thing, got a bigger screwdriver and some vice grips. After about thirty minutes of clock time, I had managed to loosen one side of the seat enough, but it would go no further. The other side just would not budge - at all. Ok, so at this point my estimated time and standard time are blown clear out the water and this is now turning into a major time consuming project.
Time to disassemble the toilet seat with all of the fancy brass screws, hinges, etc. Time to call out the BIG TOOLS. I'm a big tools kinda guy, I have virtually every kind of tool known to man and it has been said that I could pull a transmission on the side of the road and repair it with what I have.
Plan D - we are way past plan A, B, and C.
Got my indispensable and 2nd favorite tool out, the ole bolt cutters. I never go anywhere without bolt cutters, having needed them to bust through padlocks when locked in hunting leases or losing a padlock key and needing to break in. Oh, of course in Texas I've been told that driving around with bolt cutters in the back of the truck is somewhat illegal, never the mind... I'm a renegade. Suppose I could blow off the lock with the Glock, but that is a little brash and way too noisy. BTW - my favorite tool is the simple pair of dikes - diagonal cutting tool. Never leave home w/o one of these either. McGyver is proud - way beyond just simple duct tape.
Anyway, moving right along, got the one side free with the bolt cutters and took out the heavy artillery of the hammer drill. I went to work on the one side where it was frozen up and just shredded the screw head to nothing. Of course, I had to be very very careful not to shatter the porcelain bowl of the toilet - otherwise the project scope would have increased dramatically. At this point, estimated and standard time have no meaning or bearing on this simple little project.
I'm pleased to report that the project came to a successful completion probably three hours after it all started. AND - most importantly there were no LTA's (lost time accidents) or LWDI's (lost work day incidents) regarding this project - lock out tag out was not required, however, safety glasses were worn during the bolt cutting and the grinding - safety, it's a #1 priority.
So, let this little toilet seat exploit be a funny reminder to you that if you do not have control over your times and costs on the foundry floor, making that casting might be costing you a lot more money at the end of the day.
Until next time, See You on Down the Road....
Shane Allen
Head of Synchro ERP North American Operations
sales@synchroerp.com
800-323-2808 xt. 1
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