Service

Forming audits — IS machine timing, mould equipment, NNPB/BB/PB process control.

A deep dive inside the IS machine — section timing, mechanism wear, mould cooling and the defect signatures they produce.

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In practice

Forming Audit

+2–6pts

Pack-rate uplift

15–30%

Forming defect reduction

+10–20%

Mould life extension

Overview

What this service does.

The hot-end audit covers everything from gob to lehr. The forming audit is a deep dive inside the IS machine itself — section timing, mould equipment, mechanism wear, mould cooling, and the defect signatures they produce. Most plants need both. Many plants only need this one.

Benefits

Why plants choose this service.

Benefit 01

Mechanism-deep

Plunger, neck ring, baffle, takeout, dead plate, pusher — every mechanism inspected, scored, and prioritised.

Benefit 02

Defect → cause mapping

Settle wave, baffle mark, choked neck, leaner, washboard, bird-cage, stuck ware — mapped to the mechanism that's actually causing it.

Benefit 03

Process-window discipline

NNPB, BB, PB and wide-mouth press-and-blow process windows benchmarked against best-known state.

Deliverables

What you get.

IS machine timing review (electronic timing drum, valve-block diagnostics)

Mechanism scorecard per IS — plunger, neck ring, baffle, takeout, dead plate, pusher

Mould cooling architecture analysis (vertiflow, axial, stack) with pros/cons per machine

Defect-to-mechanism mapping with anonymised numbers

Process-window benchmark per SKU family

Machine-by-machine punch list ranked by impact and effort

Process

How it runs.

Pre-audit data review

90 days of defect, downtime and speed data; recent maintenance logs; mould inventory state.

On-site, machine-by-machine

3–5 days per IS machine, full mechanism walk-down, timing diagnostic, defect signature analysis.

Findings + workshop

Mechanism scorecards, defect mapping, prioritised actions for each IS machine.

Implementation support

Optional 90-day support to close the highest-impact items.

FAQ

Questions, answered.

Yes. Our team has run all three. Servo-specific items are covered separately in the audit (precision motion control, servo timing, valve-block calibration).

Not always. Some plants only need the forming audit. We help you scope it on a 30-minute call.

30-minute call with a senior practitioner.

Bring a problem — leave with a direction.

Book a hot-end audit Explore services

Forming audits — IS machine timing, mould equipment, NNPB/BB/PB process control.

What this service does.

Why plants choose this service.

Mechanism-deep

Defect → cause mapping

Process-window discipline

What you get.

How it runs.

Pre-audit data review

On-site, machine-by-machine

Findings + workshop

Implementation support

Questions, answered.

Often paired with.

Hot End Audit

Job Change Tool

Job Change Lifecycle

30-minute call with a senior practitioner.

Forming audits — IS machine timing, mould equipment, NNPB/BB/PB process control.

What this service does.

Why plants choose this service.

Mechanism-deep

Defect → cause mapping

Process-window discipline

What you get.

How it runs.

Pre-audit data review

On-site, machine-by-machine

Findings + workshop

Implementation support

Questions, answered.

Often paired with.

Hot End Audit

Job Change Tool

Job Change Lifecycle

30-minute call with a senior practitioner.