Philip Morris
Stock Prep Operating Problems, Worklife Issues & Nonconformances to Principles
Fields
- Type
- REPT, REPORT, OTHER
- FORM, FORM
- Area
- JENKINS,DEBBIE/OFFICE
- Characteristic
- MARG, MARGINALIA
- Named Person
- Ancess, J.
- Cummins, R.
- Hanks, S.
- Jenkins, D.
- Mertz, D.
- Mills, M.
- Moring, K.
- Pullano, L.
- Sharkey, J.
- Simpson, J.
- Tudor, A.
- Document File
- 2024794524/2024794872/Sp Operating Problems Worklife
- Issues Principles Nonconformances
- 2024794525/2024794605/Cp Operating Problems
- Named Organization
- Pdmt C+I Team
- Sit C+I Team
- Litigation
- Stmn/Produced
- Site
- M45
- Date Loaded
- 31 Jan 1999
- UCSF Legacy ID
- ypu79e00
Document Images
STOCK PREP OPERATING PROBLEMS, WORKLIF€ ISSUES & NONCONFORMANCES TO PRINCIPLES
RANK ARBITRARY
PROBLEM <
NUMBER PROBLEM STATEMENT/ISSUE
ALREADY
ADDRESSING
METHOD
REPRESENTATIVE(S)
TO GIVE INPUTS
1 We don't chemically clean evaporators on Lines 1/2
resulting in build-up of slime and tobacco
deposits & unknown/unquantified operational
effects.
2 We are unable to control consistency in the stock Yes SIT C&I Team Jeff Simpson
discharge tank on Line 1 resulting in excessive Keith Moring
variation in refining & consistency in our product Junie Ancess
delivered to customer (Machine Room). Alan Tudor
3 Oversized broke feedback pump on Line 3 results in Yes PDMT C&I Team Bob Cummins
excessive repair cost and downtime.
4 Chute design on spare Sharples causes build-up of Yes ACT Proposal Sandra Hanks
nitrates on the chute resulting in a housekeeping (Maint. backlog) Joe Sharkey
and worklife issue on Line 3.
,0
5 The evaporator cleaning schedules on Lines 1 and 2
are inconsistent and on Line 2 may induce
variation in CEL sols. as well as worklife and
downtime issues.
6 There are inconsistent SOP's on the three lines as
relates to controlling stock levels in S/C and M/C
and how these levels relate to MR shutting down
and restarting after a shutdown (feast or famine).
7 CFT & EFT Sludge parameters on Line 3 vs. Lines Yes SPC System
1 & 2- inconsistency across lines resulting in Brainstorming
lack of uniformity.
84ee4EPime~ management is not adhering to Principle
#7 - NOTE, IF ANYONE VOTES ON THIS PROBLEM, GIVE A
SPECIFIC EXAMPLE OF IT! !! ~/~~p~+~?~ o'aArvio,.D s-rs4Nn,aZl,> z,4,.z;,.J
ZL5tGLVZnZ Page 1

RANK
STOCK PREP OPERATING PROBLEMS, WORKLIFE ISSUES & NONCONFORMANCES TO PRINCIPLES
ARBITRARY
PROBLEM ALREADY REPRESENTATIVE(S)
NUMBER PROBLEM STATEMENT/ISSUE ADDRESSING METHOD TO GIVE INPUTS
9 Operating procedures and/or philosophies and
practices within Stock Prep are inconsistent
across the three lines - NOTE, IF ANYONE VOTES ON
THIS PROBLEM, GIVE A SPECIFIC EXAMPLE OF IT!!!
10 The A/C thermostat for the Line 3 Control Room is Yes PDCA Problem- Mark Mills
being adjusted too frequently causing a worklife Solving
issue from shift to shift, individual to indivi-
dual as relates to human comfort.
11 The crystallizer deck surface on Line 1 is a Yes Quote Received Debbie Jenkins
housekeeping problem - peeling, cracking, etc. (Budget backlog)
12 We carry too much DN inventory on Lines 1/2 Yes SIT C&I Team Lance Pullancb
which makes cleaning tanks a problem.
13 The responsibility for and frequency of cleaning Yes New Operational Debbie JenkiF
T-
the new tanker pad is in question resulting in
Procedure &
0
unclear expectations. o ~
14 Refiner Plate life on Lines 1/2 is too short Yes SIT C&I Team Debbie Jenkisis~
resulting in downtime and excessive co_st. Joe Shark4
15 There is no hot water flush line from the
evaporators to the CEL tanks on Line 1 resulting
in plugged lines and worklife issue.
16 Lines 1/2 are still taking press cake samples and
sending them to Lab for total solids analysis.
This information is put on System's Report but
nothing is being done with the data; why is it
necessary to continue?
Page 2
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STOCK PREP OPERATING PROBLEMS, WORKLIFE ISSUES & NONCONFORMANCES TO PRINCIPLES
ARBITRARY
RANK PROBLEM
ALREADY
NUMBER PROBLEM STATEMENT/ISSUE ADDRESSING
S 17 Changes in Pulper consistency on Lines 1 & 2 are Yes
reacted to differently by the Operators; Line 1
Operators change pulper consistency via dilution,
Line 2 changes press speeds, etc.; same problem,
different/inconsistent solutions.
18 EFT sols. on Line 1 is consistently high which Yes
may be influencing carryover to cooling towers
and increased water flows.
19 Line 1 water flows are high; Stock Prep Supvs. are Yes
the only ones being called to investigate and take
action when problem is often found elsewhere; also
limits on water flow charts are questionable.
20 SPC System chart interpretations are inconsistent Yes
from shift to shift, both operators and Supvs. on
all three lines; Principle #5 nonconformance; SPC
Specialist needs to retrain as necessary personnel
on chart inter
retation
p
.
.3~ 21 Stock Prep Supvs. are the only ones who have not
been to the River House for a meeting.
22 A sufficient number of operational radios does not
exist to support Stock Prep operations on all
three lines.
23 There is uncertainty as to the gameplan for the
future of Supvs. and alignment = 1 area vs. 2
areas.
24 There are no drain/pump lines to the tanker for
i9
CEL on Line 1; no capability to send CEL to tanker
(pump and piping needed).
25 The offices on Lines 1 & 3 are too small and the Yes
furniture is insufficient.
REPRESENTATIVE(S)
METHOD TO GIVE INPUTS
SIT C&I Team Jeff Simpson
Keith Moring
Junie Ancess
Alan Tudor
PDCA Problem- Bob Cummins
Solving
PDMT C&I Team David Mertz
Debbie Jenkins
SPC System Alan Tudor
Brainstorming Debbie Jenkins
'o, o
o
New Furniture L3 Debbie Jeng#
Satellite Shops L1/2
~
t4S~~4VZ0Z Page 3

STOCK PREP OPERATING PROBLEMS, WORKLIFE ISSUES & NONCONFORMANCES TO PRINCIPLES
ARBITRARY
RANK PROBLEM
ALREADY
NUMBER PROBLEM STATEMENT/ISSUE ADDRESSING
rea Cleaning Schedules are not turned in to
46
Sharkey; not supplied to Optrs. by Supvs.; not
collected by Supvs. from Optrs.; thrown away;
Supvs. don't/can't verify what's been done; Optrs.
can write down anything; why not document on
Action Report when things are cleaned.
27 There is an inadequate supply of hot filtered
water on Line 1 for cleaning resulting in a
housekeeping and worklife issue. -
28 We have a problem controlling dilution to the Yes
presses when 1 press line is down (bladder valves)
resulting in overflow of conveyor, inconsistency
in stock discharge tank and dilution leakage to
online presses.
29 The PDT and PHT overflow sporadically and we can't
explain why resulting in a Safety and housekeeping
issue.
30 Press Discharge Tank consistency loop on Line 3 Yes
(ratio control) presses doesn't operate properly
resulting in the dilution lines plugging,aod
_ n.
METHOD
SIT C&I Team
SIT C&I Team
REPRESENTATIVE(S)
TO GIVE INPUTS
Jeff Simpson
Keith Moring
Junie Ancess
Alan Tudor
a
Jeff SimpsWo
Keith Mor-ia~~,
Junie Anct
5 sQ
Alan Tud& (D
~
n
54!;V64Vz0'7 Page 4
