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OBJECTIVE THOUGHT
• IN EVERY DIE CASTING PLANT , THERE IS USUALLY ONE PERSON; WE'LL CALL HIM
MASTER, WHO CAN ALMOST ALWAYS MAKE A GOOD CASTING. THE PROBLEM IS THE
PRODUCTIVITY OF THE OPERATION WAS LIMITED BY THE NUMBER OF HOURS HE CAN
WORK. AND WHAT IF HE TAKE A VACATION? MASTER IS THE "BLACK ART" DIE CASTER.
HE COULD PERSUADE THE PROCESS TO PRODUCE AN ACCEPTABLE CASTING BY
TWISTING KNOBS AND VARIOUS DIE SPRAY TECHNIQUES KNOWN ONLY TO HIM.
EVENTUALLY HE WOULD TRAIN AN OPERATOR IN THE TECHNIQUE AND FOR A FEW
HOURS THEY COULD CONTINUE TO PRODUCE GOOD CASTINGS. THEN THE NEXT SHIFT
WOULD ARRIVE AND A NEW RECIPE WOULD BE INTRODUCED AND THE QUALITY
WOULD CHANGE, USUALLY WORSE. WHEN YOU WILL IN A CRISIS FOR PARTS, MASTER
WOULD BE CALLED BACK ON OVERTIME TO "FIX" THE PROBLEM, AFTER A FEW MINUTES
OR HOURS, THE PROCESS WOULD PRODUCE GOOD CASTINGS AGAIN, HE WOULD TRAIN
THAT OPERATOR AND YOU WERE GOOD UNTIL THE NEXT SHIFT CHANGE.
• ALMOST DIE-CASTING PLANT RUNNING WITH THIS THEORY CALLED “MASTER” AND
WE HAVE TO KILL MASTER .
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