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START a1~ DATE 1 102/15/911 ( I-I 1 2 101/10/921 19 2/91 PROBLEM I EVIDENCE LINE III BLENDING - WEIGH NOV.'91 - JAN.192 ToM's BELT SET POINTS ARE OFF STANDARD A HIGH PERCENTAGE OF THE TIME TOBACCO RAW MATERIALS TEST RUN IN 12/91 ARE BEING LOST FROM THE SHOWED 1.471ti OF TOTAL PROCESS IN LINE I INFEED POUNDS WERE BLENDING BEING LOST LINE I BLENDING WORKLIFE ISSUES: 1. CONGESTION 2. ERGONOMIC PROBLEMS 3. PHYSICAL WORKLOAD DUE TO INCREASED THRU-PUT 11. VARIED TYPES OF RAW MAT- ERIAL CONTAINERS (PM80S, HHDS, WIREHEADS, SM.CASES) 2. STRIPPING & BREAKDOWN AT 12 OIFF. LOCATIONS 3. INCREASED MACHINE SPEED LI & LII EXCESS FOAM ON TOP OF LINE I AND II MACHINE ROOM SBW CHEST I MICRO ACTIVITY AROUND FOAMING AREAS I I ~ I I I I I ~____I I 1 22 12/10/92 1 TOM REVIEW & ROUTINE PROCESSI REASONS GIVEN ON TOM AND I I HIGH FLOWS ARE NOT ACCOUNTEDI REPEATED RECUESTS FOR PC I I FOR BY PRODUCTION PERSONNEL I GROUP TO FIND OUT REASONS I I I AND REASONS ARE UNCLEAR I-I I (C:C&l8) &O9vG4.v2:0?; (ACTIVE) PRODUCTION DEPARTMENT CONTROL & IMPROVEMENT PLAN OBJECTIVE MAINTAIN WEIGHBELT SET POINTS ON STANDARD AND KEEP BLENDING FEED PARAMETERS IN CONTROL -I., CP~ pDm DETERMINE MAJOR CAUSES AND RECLAIM 70'/. OF CURRENT RAW MATERIAL PRESENTLY BEING DISCARDED ' IMPLEMENT SHORT AND LONG TERM SOLUTIONS TO ALLEVIATE THESE PROBLEMS INSTALL A FOAM CONTROL SHOWER SYSTEM ON THE SBW CHESTS TEAM LEADER/ TEAM MEMBERS (ACCOUNTABLE) B. ESTES D. BUDD/B.ESTES F. DUNCAN J. BROWN M. Titter (Res.) I F. me Fce, I DATE: 10/12/92 PDCA TIME LINE P - 2/15/91 D - 6/1/92 C - 11/15/92 A - 12/15/92 (NOT ON SCHEDULE - NEEDS TO GO TO SIT) I R. WAGNER D. ORMS/B. ESTES P - 1/13/92 C. HARRISON D - 6/1/92 B. WORRELL C - 8/1/92 D. BUDD A - 1/28/93 (ON SCHEDULE) A. TIMPANO B. ESTES P - 2/17/92 D. ORMS I D - 3/15/92 D. HALL I C - 10/15/92 R. BOHON P. GREENBURG I ~ A - 7/31/93 (ON SCHEDULE) S. SHAKERI I D. SAUNDERS P - 2/15/91 D - 2/30/91 I I C - 3/22/91 A - 9/4/91 (LII) .v I (LII COMPLETE) C - 7/20/92 (LI) -~-~ A - 8/31/92 (LI) (COMPLETE EXCEPT CD PLATFORM) S. PROVIDE REASONS FOR UPWARD D. TRENDS IN TOM WWT FLOWS FROM W. PROCESS & PROVIDE SYSTEM TO INVESTIGATE BY PROD PERSONNEL MERTZ E. CLARKE I_._ - --~-- - - D. SAUNDERS ( P I D -

START # DATE PROBLEM PARTICULATES IN SYSTEM NEED FOR MECHANICAL CLEANING OF TUBES 24 3/2/92 MANY ACTIVITIES REQUIRED TO WET FELT CHANGE PROCEDURE CHANGE CONTINUOUS WET FELTS PLACE EMPLOYEES AT GREAT RISK OF INJURY REPEATED REPAIR COSTS SINCE 1986 HAVE BEEN USED BEYOND EXPECTED LIFE 35 12/24/92 1 THE COOLING TOWERS ARE 1 44 112/8/91 DETERIORATING PRODUCT SLIPPING ON TRANSFERl- FREQUENCY OF PLUGS BELTS ON ALL THREE LINES ~• OBSERVATION OF OPERATORS 55 ~ 4/6/92 THE TUBES OF THE WIEGAND EVAPORATOR ARE FOULED, RESULTING IN INEFFICIENT OPERATION 58 16/15/92 1 SIGNIFICENT UNEXPLAINED MONTHLY STEAM DIFFERENCES IN STEAM USAGE EXISTS BETWEEN THE THREE LINES THAT MAY RESULT IN ENERGY INEFFICIENCIES. L-2 ROTARY DRYER PRE-HEAT FAN OFF LINE A HIGH % OF TIME RESULTING IN OFF STD TIME ON CHILLED AIR AND RESULTING IN ROTARY PLUGGAGE1 (C:C&I8) s~~~G4'Vzoz EVIDENCE USAGE TOM'S: L-I - 2,128,410 L-I1 858,965 L-III • 1,780,500 LBS/WK LBS/WK LBS/WK OFF STANDARD TIME ON PRE- HEAT FAN/COIL TEMPERATURE, PLUGGAGE & SLIME BUILD-UP ON COILS, MOISTURE ACCUMU- LATING UN COILS (ACTIVE) PRODUCTION DEPARTMENT CONTROL & IMPROVEMENT PLAN OBJECTIVE DECREASE THE NUMBER OF HIGH RISK ACTIVITIES REQUIRED TO CHANGE THE WET FELT RESTORE COOLING TOWERS TO RELIABLE OPERATING STATE EVAP L3 (ONE CELL) BRINE CHILLER L3 VACUUM SEAL PIT L1 FIND AND INSTALL BELT THAT WILL REDUCE SLIPPAGE (EVALUATION OF RIBBED BELT CONTINUING) MINIMIZE FOULING OF EVAPORA- TOR & IMPLEMENT COST/TIME EFFECTIVE CLEANING PROCEDURES TO ASSURE ACCEPTABLE CLEAN- LINESS OF TUBES VALIDATE THE EXISTING STEAM USAGE TOM'S BY CONDUCTING A ROUGH STEAM BALANCE TO DETERMINE IF & WHERE ENERGY INEFFICIENCIES EXIST AND THEIR MAGNITUDE REDUCE OFF STANDARD TIME ON TEMPERATURE BY 70% TEAM LEADER/ TEAM MEMBERS (ACCOUNTABLE) J. HENSLEY D. SAUNDERS W. E. CLARKE MACHINE ROOM SUPVS W. HAYES J. SHARKEY ~ D. JENKINS J. BANDY ~ T. J. WEBB ~ W. HAYES 1. MCLAUGHLIN D. DONAHER/ J. SHARKEY D. SAUNDERS J. BARRINGTON D. MERTZ D. DONAHER RESOURCE: ~ D. SAUNDERS D. MITCHEM J. LUSK ~ P. PUGLISI B. FORD T. SCOTT W. HAYES G. SWEENEY G. JONES DATE: 10/12/92 PDCA TIME LINE 12/31/93 (ON SCHEDULE) P - 2/24/92 D - 5/18/92 * C - 7/26/92 A - 12/31/92 (ON SCHEDULE) /,R/~~~9 (RETURN TO DO SEGMENT, 10/1/92) P - 10/92 11/92 02/93 04/93 6/30/92 D - 11/92 c- A I(C & A DATES TO FOLF N p - x' D- C' ~ C)

(ACTIVE) PRODUCTION DEPARTMENT CONTROL & IMPROVEMENT PLAN START DATE 61 16/15/92 1 -I 63 16/29/92 PROBLEM HIGH PRESSURE SHOWER PUMPS ARE FREQUENTLY OFF-LINE FOR REPAIRS RESULTING IN HIGHER THAN DESIRED REPAIR COSTS ~• LINE III BROKE PUMP IS OVER-1. SI2ED & RESULTS IN EXCESSIVE1 REPAIR COST & OPERATING PROBLEMS DUE TO CURRENT OPERATING MODE EVIDENCE ~ OBJECTIVE __- - .~' - '~ TEAM LEADER/ ~ TEAM MEMBERS (ACCOUNTABLE) PDCA TIME LINE 1992 MONTHLY EXPENDITUR I REDUCE PUMP DOWNTIME ANALYSIS-PURCHASE REOU STS AND REPAIR COSTS 1992 MONTHLY MACHINE PARTS - WORK TICKETS SCANPRO ANALYSIS BROKE PUMP DESIGNED FOR 700 GPM & PUMPING AT 5 GPM $32,885 REPAIR COSTS DURING LAST 2 YEARS ~• ~ S. CLARKE J. DECK G. BALLARD D. MERTZ DATE: 10/12/92 P - 7/6/92 D • 7/30/92 C - 9/10/92 A - 10/10/92 (NEED PARTS - NEW TIMELINE DETERMINE NEEDED IMPROVEMENTS B. CUMMIN S. SHAKERI AND COSTS TO CURRENT L3 BROKE D. DONAHER D. SAUNDERS PUMPING TO ELIMINATE PUMP OPERATIONAL PROBLEMS & REDUCE REPAIR COSTS BY 76% YRLY. (LESS THAN $5,000) ~ IMPROVE LIQUOR CLEAN-UP AND D. EVERS S. SHAKERI REDUCE MAINTENANCE REPAIR D. DONAHER D. SAUNDERS L 64 16/29/92 1 BIRD CENTRIFUGE MAINTENANCE UNITS ARE SECOND MOST REPAIR COSTS ARE 100 TIMES COSTLY REPAIR ITEM IN HIGHER THAN ALPHA LAVAi. VARIABLE REPAIR COST CENTRIFUGE AND CURRENTLY ~ EXPENSE ARE CLOSE TO OPERATIONAL STA-SIEVES BLIND OVER LIMITS - 66 19/16/92 PARK 500 CURRENTLY SHIPPING CONT. DR. BLADE REELS TO MASS & OREGON FOR REGRINDING1 RESULTING IN EXCESSIVE COST,j. LONG SHIPPING & TURN AROUND I ( TIME, & SUBSTANDARD QUALITY ON REGRINDS 67 19/18/92 1 EQUIPMENT LOCK-OUT PROCEDURES/TRAINING DO NOT MEET THE EXPECTATIONS OF I I PRODUCTION MANAGEMENT (C:C&18) ~ COSTS AT THE BIRD CENTRIFUGES P. DUDLEY D. CLARK R. GARG SHIPPING COST OF $825.00 PERI LOCATE/DEVELOP ALTERNATE LOCALI NUMBER OF REELS RETURNED VENDORS TO REGRIND OUR CONT. TO THERMO ELCTRON FOR REWORKI REELS AT OR BELOW CURRENT COSTI 2 MEETINGS WITH THERMO ABOUTI FOR REGRINDING - 5425-5500 POOR QUALITY AT PARK 500 1 (SAVINGS OF $100,000+) REEL LIFE DUE TO POOR GRINDS1 FROM MIDDLE TO END OF REELS PRODUCTION DEPARTMENTAL IMPLEMENTATION MOD lI TQFA'S IMPROVE METHODOLOGY/SYSTEMS R. BRASWELL FOR ENSURING EFFECTIVE S. NELSON EQUIPMENT LOCKOUT IN G. JONES PRODUCTION AREAS ~ P - 10/30/92 D - 11/30/92 C - 01/93 A - 06/93 ~ P- 10/30/92 D - C T. WEBB W. HAYES S. CLAXTON 8. ESTES A • nMs4vzoz

START as' DATE PROBLEM 1-1-1 1 68 19/18/92 PRODUCTION DEPARTMENT SUPVS. ARE NOT EFFECTIVELY CONDUCT• ING EVACUATION TRAINING TO HOURLY EMPLOYEES RESULTING IN POOR CUSTOMER SATISFAC- ~ TION AND AN IMPROVEMENT FACTOR OF 28 69 19/18/92 70 19/18/92 I FACTOR OF 50 EVIDENCE -FINAL TOFA RESULTS- CHARACTER- 1- ISTICS IMP ( PERF FACTOR _...--- ^ -------- ------------------ ----------- Accuracy 4 3 1 12 ~. Timely 2 2 4 Maintenance 2 3 6 Training 2 3 6 Understood • TOTAL • ~ 28 DATE: 10/12/92 TEAM LEADER/ OBJECTIVE TEAM MEMBERS (ACCOUNTABLE) PDCA TIME LINE _1_ CORRECT EVACUATION PLANS AND B. SHOPE R. WILLIAMS IMPROVE I-FACTOR BY 60% J. EVANS W. HAYES -FINAL TOFA RESULTS- CHARACTER- I I I I ( ISTICS JIMPIPERFIFACTOR I .................................... ~ RESULTING IN EMPLOYEES LACK Clear Training OF UNDERSTANDING OF RESPONSI- Accurate Manuals BILITIES AND AN IMPROVEMENT Complete Manuals ~ PRODUCTION DEPARTMENT DOCU- MENTATION & TRAINING OF MSDS DOES NOT MEET PM, USA NOR ~ AUDITOR EXPECTATIONS, Manuals Available to People - TOTAL - 5 50 TRAIN, THEN DOCUMENT I. MCLAUGHLIN J. JONES TRAINING FOR EACH EMPLOYEE; T. LITTLE W. HAYES IMPROVE I-FACTOR RATING BY I R. WAGNER ~ 50% PRODUCTION DEPARTMENT MANAGE- -FINAL TOFA RESULTS- DEVELOP SYSTEM TO COMMUNICATE P. PUGLISI MENT IS NOT DELIVERING CHARACTER- I I I!r I REGULATORY INFORMATION IN A D. STEPHENSON REOUIRED REGULATORY INFORMA- I ISTICS JIMPIPERFIFACTOR TIMELY MANNER; IMPROVE B. MAYES TION TO ITS PEOPLE AS PRE- I --•-----------------------------•--- I CUSTOMER TOTAL I-FACTOR BY SCRIBED BY FEDERAL/STATE STATUES, RESULTING IN CONFUSION & A LACK OF KNOWLEDGE BY THE HOURLY EMPLOYEES, AND A CUSTOMER SATISFACTION RATING OF 54 C:C817 (ACTIVE) PRODUCTIGN DEPARTMENT CONTROL & IMPROVEMENT PLAN Effective Commun. 1 3 1 5 1 15 Appropriate Commun.1 3 1 5 1 15 ~. Commun. Understood 1 2 1 6 1 12 ~. Timelinnes of 2 6 1 12 Communication ~ - TOTAL 54 55% anl ~-~- ( I W. HAUQ ueYQa ~ iTsVs4Vzaz

(ACTIVE) PRODUCTION DEPARTMENT DATE: 10/12/92 CONTROL & IMPROVEMENT PLAN START I t/ DATE PROBLEM EVIDENCE OBJECTIVE TEAM MEMBERS TEAM LEADER/ (ACCOUNTABLE) PDCA TIME LINE -I 71 19/18/92 NO SYSTEM EXISTS TO ENSURE PDMT MOD 11 DEVELOP SYSTEMS/ACCOUNTABIL- B. WYCHE D. MERTZ 1-1 ONGOING MONITORING OF ENVIRONMENTAL ABATEMENT EQUIPMENT IN PRODUCTION AREAS ITIES TO ENSURE ENVIRONMENTAL ABATEMENT EQUIPMENT IN PRO- DUCTION AREAS IS FUNCTIONING PROPERLY AT ALL TIMES L. JACKSON RESOURCE - P. PUGLISI W. WILLIAMS D. SAUNDERS 72 19/18/92 PRODUCTION DEPARTMENT CANNOT 1992 AUGUST COST BOOK YTD DEVIATIONS REDUCE YTD DEVIATIONS OR B. ESTES J. NARRON ACT • 12/31/92 ASSURE FULFILLING FIDUCIARY RESPONSIBILITIES RELATED TO THE 1992 SECOND REVISED BUDGET, RESULTING IN POOR CREDIABILITY IN COST CONTROL PROVIDE EXPLANATIONS TO MEET ROC EXPECTATIONS I I "I I~~~ ~/ W. HAYES D. JENKINS I D. SAUNDERS /" 73 19/18/92 ( PROOUCTION SUPERVISION IS RECENT ACCIDENT UNFAMILIAR WITH EXPECTATIONS/ RECENT LOST TIME RESPONSIBILITIES THAT FORKLIFT1 . LINGERING PROBLEMS OPERATORS RECEIVE DURING FORKLIFT TRAINING AT THE TRAINING CENTER ~ STATEMENTS OF PARTICIPAN "RESPONSIBLES" 74 19/18/92 1 NO SYSTEM EXISTS TO ENSURE PRODUCTION DEPT PERSONNEL ARE TRAINED TO OPERATE MANLIFT EOUIPMENT 75 19/18/92 1 PRODUCTION DEPARTMENT IS NOT IN FULL COMPLIANCE WITH EH&S AUDIT FINDINGS/RECOMMENDATIONSI. UNFINISHED ASSIGNMENTS I (COMPANY POLICY) I CONDUCT FORKLIFT FAMILIARI- M. HILL ZATION TRAINING FOR PRODUCTION SUPERVISORS D. HALL 8. ESTES ACT - 10/31/92 ESTABLISH A SYSTEM TO ENSURE B. VICKERS D. AMPEY ACT - 11/15/t TRAINING IS ACCOMPLISHED AND ( B. MAYES B. ESTES 0 DOCUMENTED FOR PRODUCTION PERSONNEL WHO ARE REQUIRED T OPERATE MANLIFTS I ~• ~i J,C 100% COMPLIANCE BY J. GLASS MINIMIZE FUTURE AUDIT W. HAYES FINDINGS/ISSUES ~ B. ESTES D. JENKINS ACT - 12/31/92 C:C&l7 z'T9trGLt7zGz

(ACTIVE) PRODUCTION DEPARTMENT DATE: 10/12/92 CONTROL & IMPROVEMENT PLAN # START DATE 1-1 PROBLEM EVIDENCE OBJECTIVE TEAM MEMBERS TEAM LEADER/ (ACCOUNTABLE) PDCA TIME LINE 76 19/18/92 PRCpUCTION DEPARTMENT IS NOT NEW ASSIGNMENTS NOT PREVIOUSLY MADE 100% COMPLIANCE BY 12/31/92 ~ J. GLASS D. JENKINS ACT - 12/31/92 IN FULL COMPLIANCE WITH S. UNFINISHED ASSIGNMENTS FROM EH&S W. HAYES ~ DARRAH'S JOB PROCEDURE PROGRAMI AUDIT B. ESTES CORRESPONDENCE (CO. POLICY & RICHMOND EH&S REQUIREMENTS) UNFINISHEDASSIGNMENTS FROM HIGHe RISK SURVEY 77 11/9/92 SPC SYSTEM REPORT DOCUMEN- -FINAL TOFA RESULTS- IMPROVE TOTAL I-FACTOR BY B. ESTES ~ J. NARRON ACT - 4/10/93 TATION HAS AN IMPROVEMENT FACTOR OF 50, RESULTING IN CHARACTER• 1- ISTICS JIMPIPERFIFACTOR 50% AND ENSURE CAPABILITY TO CONTINUOUSLY IMPROVE THE W. HAYES ~ D. JENKINS REDUCED CUSTOMER EFFECTIVENESS1 -•------------••---•--- -----•-*--- QUALITY OF THIS PRODUCT I D. SAUNDERS I WHEN THIS PRODUCT IS USED 1. Accurate 1 3 1 5 15 ~. Complete ~ 3 5 15 Clarity 2 ~ 5 10 Legible 2 5 ~ 10 ~ ~ TOTAL 50 78 19/19/92 - -- - 1992 UNION CONTRACT CONSOLI- I GENERAL LABORER PERSONNEL NOT ABLE DATED THE FORKLIFT/CHECKER ANDI TO PERFORM FORKLIFT OPERATIONS IN GENERAL LABORER CLASSIFICATIONI SPECIFIC AREAS SOME GENERAL LABORERS ARE NOT ~ TRAINED TO PERFORM FORKLIFT AND/OR CHECKER ASSIGNMENTS IN ~ VARIOUS AREAS DETERMINE TRAINING NEEDS AND CONDUCT TRAINING SO WE CAN ABIDE BY INTENT OF UNION/ MANAGEMENT AGREEMENT C. HARTSELL D. ORMS D. AMPEY TRNG. GROUP D. HALL ~ B. ESTES ACT - 12/31/92 1 ... -1 1 79 111/9/92 1 HOURLY PERFORMANCE LEVEL DOES 1. I NOT MATCH TOTAL QUALITY NEEDS 1. 1 80 111/9/92 1 SALARIED PERFORMANCE LEVEL I I DOES NOT HATCH TOTAL QUALITY NEEDS 1_1-1 - I_ C:C&17 LACK OF USE OF Q500 TOOLS/TECHNIOUES1. DEFINE BARRIERS & ELIMINATE LACK OF INVOLVEMENT ON PROBLEM SOLVING TEAMS ~• L THEM ALLOW FOR DECISION MAKING AND RISK TAKING INCREASE INVOLVEMENT LACK OF USE OF 0500 TOOLS/TECHNIOUES1. DEFINE BARRIERS & ELIMINATE LACK OF INVOLVEMENT ON PROBLEM THEM SOLVING TEAMS ALLOW FOR DECISION MAKING AND RISK TAKING INCREASE INVOLVEMENT ~ B. ESTES J. NARRON W. HAYES D. JENKINS D. SAUNDERS ESTES J. NARRON HAYES JENKINS SAUNDERS ACT • 6/10 VM64vzoz

(ACTIVE) PRODUCTION DEPARTMENT CONTROL & IMPROVEMENT PLAN PROBLEM EVIDENCE ~ OBJECTIVE TEAM MEMBERS CURRENT PRODUCTION DEPARTMENT I. NUMBER OF SHIFT SUPV. WORKWEEKS IN IMPLEMENT A SYSTEM FOR W, HAYES SYSTEM FOR COVERAGE OF SHIFT EXCESS OF 40 HOURS TODAY FILLING SHIFT SUPV. VACANCIES B. ESTES SUPERVISOR VACANCIES IS IN SHIFT SUPERVISOR INPUT THAT MEETS COMPANY NEEDS AND CONFLICT WITH COMPANY ADDRESSES SUPV. WORKLIFE BUDGETARY GUIDELINES AND ISSUES COMPENSATION POLICY RE; OVERTIME AND MAY RESULT IN A WORKLIFE/MORALE ISSUE AFFECTING JOB PERFORMANCE AFTER 1/1/93 82 110/12/921 WIEGAND EVAPORATOR PARAMETERS SPC SYSTEM ARE NOT INCORPORATED INTO THE SPC SYSTEM, CAUSING INCONSISTENT OPERATION DEFINE & INCORPORATE WIEGAND OPERATING PARAMETERS AND STANDARDS INTO SPC SYSTEM. EXAMPLE PARAMETERS: EXIT WIEGAND SOLUBLES WIEGAND VACUUM STEAM CHEST TEMPERATURE TURBOFAN VIBRATION WIEGAND FEED GPM FINISHER STEAM PRESSURE DATE: 10/12/92 TEAM LEADER/ ~(ACCOUNTABLE) PDCA TIME LINE D. JENKINS ACT - 12/1/92 BRASW 1 D. JENKINS ~ ACT - 12/31/92 J. HANKS A. TUDOR C:C&17 :5,rr IA : -Vf Uja-~ 2 -~ , ~ onah O u l~~ ~ 5 .nc at, , ~ 5 ~1ar~1 ~, J ~• cp z ;~-; a'„n