Trimming inherits whatever the press and the die left behind. Excess flash, a mismatch, or a trim tool going blunt all turn a good forging into a second pass — extra handling that leaves as a good part and costs like a reject. The cost lands in a labour line, not against the stage that sent it.
Your ERP logs the pieces trimmed.
It won’t tell you which forgings needed a second cut, or that the trim tool has been dragging for a week.
Why the gap existsWhere the losses hide
A forging trimmed twice is one good part in the output and two passes in the labour. The second pass is invisible unless it is logged as one.
A forging that goes round twice is one good part in the output and two passes in the labour — real hours on a real part, absorbed as department time with no route back to the forging that caused it.
A blunt trim die tears rather than shears, leaving burrs that go to secondary work. The wear shows as a rising rework rate before it shows as a tool change.
Forgings that miss the trim window cool and need reheating or re-fixturing. The delay is never downtime, so it lands as fewer pieces with no reason attached.
The join
Same run, same clock, same asset — three streams that only mean something together.
Pieces trimmed, trim tooling issued, hours booked to the department.
The rework pass logged as a rework with its cause tagged upstream, and trim-tool changes tied to the count they came in on.
Rework hours per forging read against the upstream stage that sent it, and trim-tool life read against the rework it starts producing.
What Munshi surfaces
Teal is normal, maroon is flagged. Illustrative data.
Tagged at the bench, so the hours land against the press or the tool, not against trimming.
Thousands of pieces before a change. The fall is the tool wearing, tool over tool.
When an outcome moves and a signal moves with it, Munshi shows both and says they moved together. It does not tell you one caused the other. The operator confirms the cause, and the confirmed cause is written back to that asset’s register — so the pattern is already named the next time it appears.
Related stages
Die wear you meet again at inspection, and downtime nobody booked.
The cycle that ran, versus the cycle that was specified.
Get started
See this on your own line.
Bring a month you already understand. The useful test is whether Munshi finds what you already know — and then what you didn’t.