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 .