Tobacco Documents Online

UL START +M DATE PROBLEM I I 66 19/16/92 1 PARK 500 CURRENTLY SHIPPING -I CONT. DR. BLADE REELS TO MASS & OREGON FOR REGRINOING RESULTING IN EXCESSIVE COST, LONG SHIPPING & TURN AROUND TIME, & SUBSTANDARD QUALITY ON REGRINDS EVIDENCE SHIPPING COST OF $825.00 PER REEL NUMBER OF REELS RETURNED TO THERMO ELCTRON FOR REWORK 2 MEETINGS WITH THERMO ABOUT POOR QUALITY AT PARK 500 REEL LIFE DUE TO POOR GRINDS FROM MIDDLE TO END OF REELS .I 67 19/18/92 I EQUIPMENT LOCK-OUT PRODUCTION DEPARTMENTAL I ~ PROCEDURES/TRAINING DO NOT IMPLEMENTATION MOD !I TGFAIS I I I MEET THE EXPECTATIONS OF PRODUCTION MANAGEMENT 68 9/18/92 I PRODUCTION DEPARTMENT SUPVS. ARE NOT EFFECTIVELY CON UCT- I I I I D ING EVACUATION TRAINING TO HOURLY EMPLOYEES RESULTING IN POOR CUSTOMER SATISFAC- I TION AND AN IMPROVEMENT FACTOR OF 28 I. I I. I - - 69 19/18/92 1 PRODUCTION DEPARTMENT DOCU- -FINAL TQFA RESULTS- CHARACTER- I- ISTICS IMP PERF FACTOR ---------•------------------------- Accuracy 4 3 12 Timely 2 2 4 Maintenance 2 3 6 Training 2 3 6 Understood I TOTAL - I 28 -- FINAL TOFA RESULTS- MENTATION & TRAINING OF MSDS CHARACTER- I I I DOES NOT MEET PM, USA NOR ISTICS IIMPIPERFIFACTOR I AUDITOR EXPECTATIONS, RESULTING IN EMPLOYEES LACK OF UNDERSTANDING OF RESPONSI- BILITIES AND AN IMPROVEMENT FACTOR OF 50 -...... ............. Clear Training 1 4 I 5 20 Accurate Manuals 1 3 5 15 Complete Manuals 2 5 10 Manuals Available 1 I 5 I 5 to People TOTAL - I I I I I I 50 (CoC&17) Cz9vG41vzv"z (ACTIVE) PRODUCTION DEPARTMENT CONTROL & IMPROVEMENT PLAN DATE: 09/25/92 TEAM LEADER/ OBJECTIVE I TEAM MEMBERS (ACCOUNTABLE) PDCA TIME LINE I Ir r-Lk~ti LOCATE/DEVELOP ALTERNATE LOCALI P L D~'E yl W. HAYES VENDORS TO REGRIND OUR CONT. REELS AT OR BELOW CURRENT COSTI FOR REGRINDING (i425-S500) C/a IR. A.~.~ - DMT AGREE TO PROBLEM, EVIDENCE, AND OBJECTIVE ON 9/28/92 I S. L- Cl a 'a-t. IMPROVE METHODOLOGY/SYSTEMS B. ESTES DMT AGREE TO FOR ENSURING EFFECTIVE Q - PROBLEM, EVIDENCE, EQUIPMENT LOCKOUT IN PRODUC AND OBJECTIVE ON TION AREAS IS• IVG 150nI 9/28/92 ~.~~i1~,s i ~: ~u`-~-~.~8 CORRECT EVACUATION PLANS AND _ . GI W. HAYES DMT AGREE TO r L ~~ IMPROVE I-FACTOR BY 60% , O C P I PROBLEM, EVIDENCE, i/Qy,~ I AND OBJECTIVE ON 9/28/92 _I TRAIN, THEN DOCUMENT TRAINING FOR EACH EMPLOYEE; IMPROVE I-FACTOR RATING BY 50% I~T Joh~s W. HAYES DMT AGREE TO a' ('b PROBLEM, EVIDEIE q AND OBJECTIVE I 9/28/92 N• X >~+I 0

START I ~ I DATE i-l I 1 70 19/18/92 PROBLEM PRODUCTION DEPARTMENT MANAGE- MENT IS NOT DELIVERING REQUIRED REGULATORY INFORMA- TION TO ITS PEOPLE AS PRE- SCRIBED BY FEDERAL/STATE STATUES, RESULTING IN CONFUSION & A LACK OF KNOWLEDGE BY THE HOURLY EMPLOYEES, AND A CUSTOMER SATISFACTION RATING OF 54 NO SYSTEM EXISTS TO ENSURE ONGOING MONITORING OF ENVIRONMENTAL ABATEMENT EQUIPMENT IN PRODUCTION AREAS PRODUCTION DEPARTMENT CANNOT ASSURE FULFILLING FIDUCIARY RESPONSIBILITIES RELATED TO THE 1992 SECOND REVISED BUDGET, RESULTING IN POOR CREDIAILITY IN COST CONTROL EVIDENCE -FINAL TOFA RESULTS- (ACTIVE) PRODUCTION DEPARTMENT CONTROL & IMPROVEMENT PLAN _I OBJECTIVE DEVELOP SYSTEM TO COMMUNICATE REGULATORY INFORMATION IN A TIMELY MANNER; IMPROVE CUSTOMER TOTAL I-FACTOR BY 55% DATE: 09/25/92 TEAM LEADER/ TEAM MEMBERS (ACCOUNTABLE) PDCA TIME LINE I I. ~ I --- W. HAYES I CHARACTER- I I I' ISTICS • .---IIMPIPERFIFACTOR I . _... . . ............. Effective Cwmwn. I 3 I 5 I 15 Appropriate Comnun.l 3 I 5 I 15 Coimiun. Understood 2 1 6 12 I Timelinnes of I 2 1 6 I 12 I Communication - TOTAL - 54 PAT PUGLISI SURVEY PDM7' /V1od.1L Work 1992 AUGUST COST BACK YTD DEVIATIONS rZ~ ~ ~-f LT ~uI'~ ~ ~ -~- ~in ~rin Sa~ P~od~G+Y1S) D. SAUNDERS i.),A.-ID.mtr{'z DEVELOP SYSTEMS/ACCOUNTABIL- k ITIES TO ENSURE ENVIRONMENTAL L T0.G 50-f ABATEMENT EQUIPMENT IN PRO- DUCTION AREAS IS FUNCTIONING PROPERLY AT ALL TIMES PRODUCTION SUPERVISION IS UNFAMILIAR WITH EXPECTATIONS/ RESPONSIBILITIES THAT FORKLIFTI OPERATORS RECEIVE DURING FORKLIFT TRAINING AT THE TRAINING CENTER NO SYSTEM EXISTS TO ENSURE PRODUCTION DEPT PERSONNEL ARE TRAINED TO OPERATE MANLIFT EQUIPMENT I C:C&17 VzyVs4Vz0z S~L~ o~-~c~ b F'o /(~ ~~~f 5 ( REDUCE YTD DEVIATIONS OR PROVIDE EXPLANATIONS TO MEET ROC EXPECTATIONS CONDUCT FORKLIFT FAMILIARI- ZATION TRAINING FOR PRODUCTION SUPERVISORS MAY, 1992 E,S,& H SAFETY AUDIT I ESTABLISH A SYSTEM TO ENSURE TRAINING IS ACCOMPLISHED AND DOCUMENTED FOR PRODUCTION PERSONNEL WHO ARE REQUIRED TO OPERATE MANLIFTS jP.Pu 1;6" -(z44S B. ESTES J. NARRON W. HAYES D. JENKINS D. SAUNDERS _ _ M. HILL I D. HALL B. ESTES B. VICKERS D. AMPEY 8. MAYES I B. ESTES DMT AGREE TO PROBLEM, EVIDENCE, AND OBJECTIVE ON I 9/28/92 DMT AGREE TO PROBLEM, EVIDENCE, AND OBJECTIVE ON 9/28/92 PR9", 3ydftNCE ,I DMT AGREE TO PROBLEM, EVIDENCE, AND OBJECTIVE ON 9/28/92 ,I a DMT AGREE TO I PROBLEM, EVIDENS, AND OBJECTIVE JR A I 9/28/92 vj• CA cri

START # DATE I-I I. 1 75 19/18/92 1 77 19/18/92 78 19/18/92 I (ACTIVE) PRODUCTION DEPARTMENT CONTROL & IMPROVEMENT PLAN PROBLEM EVIDENCE PROOUCTION DEPARTMENT IS NOT STATEMENTS OF PARTICIPANTS/ IN FULL COMPLIANCE WITH EH&S "RESPONSIBLES" AUDIT FINDINGS/RECOMMENDATIONSI. UNFINISHED ASSIGNMENTS (COMPANY POLICY) PRODUCTION DEPARTMENT IS NOT NEW ASSIGNMENTS NOT PREVIOUSLY MADE IN FULL COMPLIANCE WITH S. UNFINISHED ASSIGNMENTS FROM EHBS DARRAH'S JOB PROCEDURE PROGRAMI AUDIT CORRESPONDENCE (CO. POLICY & UNFINISHED ASSIGNMENTS FROM HIGH- RICHMOND EH&S REQUIREMENTS) RISK SURVEY SPC SYSTEM REPORT DOCUMEN- -FINAL TQFA RESULTS- TATION HAS AN IMPROVEMENT CHARACTER- I I I 1- FACTOR OF 50, RESULTING IN I ISTICS IIMPIPERFIFACTOR REDUCED CUSTOMER EFFECTIVENESSI .................................... WHEN THIS PROOUCT IS USED Acturate 1 3 1 5 15 ~ ~. Compfete 1 3 5 15 ~ I. ClaritY I 2 I 5 10 I. legibfe 2 I 5 ( 10 I I I TOTAL I I 50 _ 1992 UNION CONTRACT CONSOLi• G(- ~i 6l.SSl /o~r1 DATED THE FORKLIFT/CHECKER ANDI hp~ blG -4"Q -~y,1t~'-l FL GENERAL LABORER CLASSIFICATIONI a SS ~ r1-1~G_v1~ 1`1 a%l I SOME GENERAL LABORERS ARE NOT TRAINED TO PERFORM FORKLIFT I AND/OR CHECKER ASSIGNMENTS IN VARIOUS AREAS 79 19/18/92 1 HOURLY PERFORMANCE LEVEL DOES I. I I NOT MATCH TOTAL QUALITY NEEDS I I ~ I I I ~ I I I I I 4,~ C:C&17 sz9vs4vzaz LACK OF USE OF 0500 TOOLS/TECHNIOUESI. DEFINE BARRIERS & ELIMINATE B. ESTES LACK OF INVOLVEMENT ON PROBLEM THEM W. HAYES SOLVING TEAMS ALLOW FOR DECISION MAKING D. JENKINS AND RISK TAKING D. SAUNDERS 1. INCREASE INVOLVEMENT I OBJECTIVE TEAM MEMBERS 100)G COMPLIANCE BY J. GLASS MINIMIZE FUTURE AUDIT W. HAYES FINDINGS/ISSUES B. ESTES TEAM LEADER/ 100% COMPLIANCE BY 12/31/92 I J. GLASS D. JENKINS W. HAYES B. ESTES I IMPROVE TOTAL I-FACTOR BY 50% AND ENSURE CAPABILITY TO CONTINUOUSLY IMPROVE THE QUALITY OF THIS PRODUCT B. ESTES W. HAYES D. JENKINS I D. SAUNDERS DETERMINE TRAINING NEEDS AND C. HARTSELL CONDUCT TRAINING SO WE CAN D. ORMS ABIDE BY INTENT OF UNION/ D. AMPEY MANAGEMENT AGREEMENT TRNG. GROUP J. NARRON DATE: 09/25/92 PDCA TIME LINE DMT AGREE TO PROBLEM, EVIDENCE, AND OBJECTIVE ON 9/28/92 DMT AGREE TO PROBLEM, EVIDENCE, AND OBJECTIVE ON 9/28/92 DMT AGREE TO PROBLEM, EVIDENCE, AND OBJECTIVE ON 9/28/92 D. HALL DMT AGREE TO B. ESTES PROBLEM, EVIDENCE, AND OBJECTIVE ON 9/28/92 J. NARRON DMT AGREE TO I PROBLEM, EVIDEN&,_4 AND OBJECTIVE Q(~,~ 9/28/92 93 n

wv= ,~:t-!lT : START PROBLEM EVIDENCE * DATE 1-1-1 - ---- . - 1 80 19/18/92 1 SALARIED PERFORMANCE LEVEL DOES NOT MATCH TOTAL QUALITY NEEDS ( 81 19/18/92 1 CURRENT PRODUCTION DEPARTMENT SYSTEM FOR COVERAGE OF SHIFT SUPERVISOR VACANCIES IS IN CONFLICT WITH CChIPANY BUDGETARY GUIDELINES AND COMPENSATION POLICY RE: OVERTIME AND MAY RESULT IN A I.IORKL I FE/MORALE ISSUE AFFECTING JOB PERFORMANCE AFTER 1/1/93 C:C&17 9z9ti64vZO?; LACK OF USE OF 0500 TOOLS/TECHNIOUES1, LACK OF INVOLVEMENT ON PROBLEM (ACTIVE) PRODUCTION DEPARTMENT CONTROL & IMPROVEMENT PLAN OBJECTIVE DEFINE BARRIERS & ELIMINATE THEM ALLOW FOR DECISION MAKING AND RISK TAKING INCREASE INVOLVEMENT SOLVING TEAMS I. (• NUMBER OF SHIFT SUPV. WORKWEEKS IN EXCESS OF 40 HOURS TODAY SHIFT SUPERVISOR INPUT I. I TEAM MEMBERS B. ESTES W. HAYES D. JENKINS D. SAUNDERS i I DATE: 09/25/92 TEAM LEADER/ (ACCOUNTABLE) ( PDCA TIME LINE J. NARRON DMT AGREE TO PROBLEM, EVIDENCE, AND OBJECTIVE ON ~ 9/28/92 ~ 6-l0 -q3,o D. JENKINS DMT AGREE TO ~ PROBLEM, EVID ~ AND OBJECTIVE ~ 9/28/92 0 C ~I