Hidden Cost and Failure Bottleneck Map

Bronze input model: record observed values from your process. Do not convert this sheet into a savings or payback claim without measured evidence.

System input	Current route	PET trial route	Evidence source	Owner
Strap consumed per package			Line count or issue record
Seal, buckle or weld input			Bill of material
Scrap and rework loops			Shift record
Tool setup and interruption			Production log
Operator handling time			Observed cycle
Edge protection and package changes			Packaging specification
Damage or load-shift events			Claims or quality record
Testing and retesting work			Test plan and report