Why is our FR5 estimate using the bracket dimensions after rework?

Every card has the straightening station stamp, but it doesn't say whether each piece was changed or only checked

Then the station operator is worth asking. The stamp may identify where the batch went without telling you what work happened there.

We once removed a checking bench from a layout because its operation had no time against it. The person using it said nobody had ever asked them for a time, which was a rather different explanation from no work happening. Dinesh, I'd keep a provisional allowance for both the person and the space until somebody can describe your station, especially if the new layout is already squeezing everything together.

Was straightening charged somewhere else, perhaps as a batch allowance rather than against each bracket?

Oscar, yes, found a batch allowance under finishing; Harish, former operator says every bracket was checked there but only some were corrected, with no count recorded

That gives you a starting cost, although it still leaves the new process to demonstrate how much checking and correction it needs.

Did finding the allowance change the comparison much?

Enough to put payback outside the target we were using, so we've asked for a current bracket trial before revising the estimate again

Is there still room for the checking station in the proposed layout, Dinesh? I'd hate for the trial to bring the operation back only after its space has gone.