BOM revisions that never reach the press
Drawing changes sitting in engineering folders while the press still runs the old nest — a classic source of material usage variance.
Engineering releases a lighter nest. Purchasing buys to the new drawing. The press shop still loads the old program because the revision folder never left the office. Material usage variance appears as “excess consumption” when the true story is a communication lag measured in days, not kilograms.
Signs during a walkthrough
- Revision stamps on drawings in the office that do not match the program label on the machine
- Purchasing invoices aligned to the new part weight while issues from stores still reference the old SKU note
- Operators who know about the change verbally but have no signed handoff sheet
What belongs in the variance narrative
Name the revision number, the date engineering signed it, and the date the press actually changed. Boards understand a dated handoff failure faster than a percentage variance with no nouns.
Prevention that plants actually keep
A one-page revision register at the work centre — revision, effective date, operator initials — beats another email policy. We look for that register before we blame the BOM math.
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