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That week we had to recast the entire 800-pound gear housing three times
It was the worst stretch I can remember, all because of a bad batch of binder for our no-bake sand. The first pour looked fine until we broke the mold and found the surface was all crumbly, like wet sugar. My foreman, Greg, just shook his head and said, 'Melt it down, we're starting over.' The second attempt had the same issue, and by the third we were all running on fumes and frustration. Turns out the new guy mixed the ratios wrong, thinking a little extra would make it stronger. We lost two full days and a ton of material. Has anyone else had a simple mix-up cause that much of a domino effect in the shop?
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paul2865d ago
We had a painter use the wrong primer on metal doors once. It looked okay until the top coat started peeling in sheets two weeks later. Had to strip every single door back to bare metal. The fix was making a simple checklist for each job and having the foreman sign off on materials before starting. Saved us a lot of repeat headaches.
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diana_black5d ago
Did that checklist save time, @paul286?
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