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Philip Morris

(Active) Production Department Control & Improvement Plan

Date: 28 Sep 1992
Length: 8 pages
2024794860-2024794867
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snapshot_pm 2024794860-2024794867

Fields

Type
REPT, REPORT, OTHER
CHAR, CHART, GRAPH, TABLE, MAPS
Area
JENKINS,DEBBIE/OFFICE
Characteristic
MARG, MARGINALIA
Named Person
Ampey, D.
Ballard, G.
Bandy, J.
Bish, J.
Bohon, R.
Bradford, A.
Braswell, P.
Braun, K.G.
Brown, J.
Budd, D.
Clark, D.
Clarke, W.E.
Claxton, S.
Cummins, B.
Deck, J.
Donaher, D.
Dudley, P.
Duncan, F.
Estes, B.
Evans, J.
Evers, D.
Ford, B.
Garg, R.
Glass, J.
Greenburg, P.
Hall, D.
Harrison, C.
Hartsell, C.
Hayes, W.
Hensley, J.
Hill, M.
Jackson, L.
Jenkins, D.
Jones, G.
Little, T.
Lusk, J.
Mclaughlin, I.
Mertz, D.
Mitchem, D.
Narron, J.
Nelson, S.
Orms, D.
Puglisi, P.
Saunders, D.
Scott, T.
Sharkey, J.
Shope, B.
Spruell, L.
Stephenson, B.
Sweeney, G.
Tiller, M.
Timpano, A.
Vickers, B.
Wagner, R.
Webb, T.
Webb, T.J.
Williams, R.
Worrell, B.
Wyche, B.
Document File
2024794524/2024794872/Sp Operating Problems Worklife
Issues Principles Nonconformances
2024794736/2024794871/T0913 0.080
Named Organization
Scanpro
Thermo Electron
Litigation
Stmn/Produced
Site
M45
Date Loaded
31 Jan 1999
UCSF Legacy ID
wou79e00

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Page 1: wou79e00
START DATE PRdBLEM 1 102/15/911 LINE III BLENDING - WEIGH BELT SET POINTS ARE OFF STANDARD A HIGH PERCENTAGE OF THE TIME TOBACCO RAW MATERIALS ARE BEING LOST FROM THE PROCESS IN LINE I BLENDING 3 102/05/921 LINE I BLENDING WORKLIFE ISSUES: 1. CONGESTION 2. ERGONOMIC PROBLEMS 3. PHYSICAL WORKLOAD DUE TO INCREASED THRU-PUT 4 102/12/921 WE ARE UNABLE TO MAINTAIN A CONSISTENT PRESS ROLL PERFORMANCE ON LINE III VARI-NIPS (C:C811) EVIDENCE NOV.191 • JAN.192 TOM's TEST RUN IN 12/91 SHOWED 1.477. OF TOTAL INFEED POUNDS WERE BEING LOST 1. VARIED TYPES OF RAW 2. 3. MATERIAL CONTAINERS (PM801s, HHDS, WIRE- HEADS, SMALL CASES) STRIPPING & BREAKDOWN AT 12 DIFF. LOCATIONS INCREASED MACHINE SPEED LI & LII OPERATING HOURS BETWEEN HI-PRESSURE ROLL CLEANINGS IS VARYING BETWEEN 100 ~ AND 350 HOURS (ACTIVE) PRODUCTION DEPARTMENT CONTROL & IMPROVEMENT PLAN ~ OBJECTIVE TEAM MEMBERS MAINTAIN WEIGHBELT SET B. ESTES POINTS ON STANDARD AND F. DUNCAN KEEP BLENDING FEED I J. BROWN PARAMETERS IN CONTROL M. Tiller (Res.) . DETERMINE MAJOR CAUSES ~ R WAGNE AND RECLAIM 70% OF CURRENT ~ C. HAIjR"ISON RAW MATERIAL PRESENTLY ~ B. RRELL BEING DISCARDED DI D jt Q ~ IMPLEMENT SHORT AND .A.,-T4*P,1N0-. LONG TERM SOLUTIONS TO ~`0- QRfTS' ALLEVIATE THESE PROBLEMS j-9-ltAk4_ ~ A--$OH6N-- ~ 4--GREENBURl; ' DATE: 09/28/92 TEAM LEADER/ (ACCOUNTABLE) D. BUDD/B.ESTES I (NOT ON SCHEDULE- NEED NEW TIMELINE 10/12/92) GRK6/9:--Etit1•• P • 1/13/92 ~ D - 6/1/92 C 8/1/92 A - 1/28/93 (ON SCHEDULE) 4--E3i{-fi' P 2/17/92 D r 3/15/92 C ~ 10/15/92 A 7/31/93 (ON SCHEDULE) V' GET PRESS ROLL,OP ATING r'I McLAUGHLIN~ SHARKEY/*r P- 2/26/92 ~• n HOURS BACK T0 350+ OURS ~ J BISH UENKINS' D 3/18/92 "A.' BRADFORD C 4/18/92 O +s A 10/9/92 N ~ ( (ON SCHEDU 1 PDCA TIME LINE P • 2/15/91 ~ D • 6/1/92 ~ -!/-'" ~ C Fw1,w2 A , ~,~,,,_ au
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(ACTIVE) PRODUCTION DEPARTMENT CONTROL & IMPROVEMENT PLAN START DATE ~- ~ 1 14 18/12/91 19 2/91 PROBLEM PRODUCT EVIDENCE OBJECTIVE OPERATION PERSONNEL ARE NOT OOCIS IN LINE 1/11 BATCH CONDUCT TRAINING ON ORIGIN, FAMILIAR WITH RAW MATERIAL DELIVERY TIME, MICRO SPECIFICATIONS, SUBJECTIVES, SPECIFICATIONS AND WHAT TO PROBLEMS, DON'T KNOW HOW AND CONTAMINENTS RELATING DO IF THEY IDENTIFY ATYPICALl TO HANDLE CONTAMINENTS TO RAW MATERIALS EXCESS FOAM ON TOP OF LINE MICRO ACTIVITY AROUND I AND It MACHINE ROOM SBW FOAMING AREAS CHEST ~ INSTALL A FOAM CONTROL SHOWER SYSTEM ON THE SBW CHESTS TEAM LEADER/ TEAM MEMBERS (ACCOUNTABLE) D. ORMS B. ESTES I.IA~INtMG'1;ROdP~ _4-a. PiPEY 4,-8#h4kfR1- 22 12/10/92 1 TOM REVIEW & ROUTINE PROCESSI REASONS GIVEN ON TOM AND PROVIDE REASONS FOR UPWARD ...D.._MER.IZ-. I HIGH FLOWS ARE NOT ACCOUNTED1 REPEATED REQUESTS FOR PC FOR BY PRODUCTION PERSONNEL GROUP TO FIND OUT REASONS AND REASONS ARE UNCLEAR TRENDS IN TOM WWT FLOWS FROM PROCESS & PROVIDE SYSTEM TO INVESTIGATE BY PROD PERSONNELI W~-E~- 6LAAK~ -1-1 J V 24 3/2/92 1 MANY ACTIVITIES REQUIRED TO CHANGE CONTINUOUS WET FELTS PLACE EMPLOYEES AT GREAT RISK OF INJURY WET FELT CHANGE PROCEDURE DECREASE THE NUMBER OF HIGH RISK ACTIVITIES REQUIRED TO CHANGE THE WET FELT 33 11/90 DISPENSION STATiON FOR THE SIX CHEMICAL ACCIDENTS IN INSTALL A DETERGENT DISPEN- I-,BULK DETERGENT TANK IS NOT, 1991 SION STATION FROM DETERGENT // LOCTED WHERE/TNE MAJORITY\~~, OF JSE IS 9ND PEOPLE ARE USING 100X DETERGENT (C:C&11) d.--HENStEY" M,-$.--CLARKf !!•r-QftUNBffli.. JYSAWfBE1tS I -0t-SAk~NBER4- b1ACN4-Nt--R80M-6k1PV9-} x "~r",mv D. CLARK L. SPRUELL ~\ANK ON 2ND FLOOR (LINE..1•1 K. G~BRAUN ~ S/P) THAT ONLY U PCI ES ~ DILUTED_DETERGENT " j 98VGZ,Vzoz DATE: 09/28/92 POCA TIME LINE ~ P - 9/1/91 ~ D - 10/15/91 C - 4/15/92 A - 9/30/92 (ON SCHEDULE) P - 2/15/91 0 - 2/30/91 C - 3/22/91 ~ A - 9/4/91 (LII) ~ (LII COMPLETE) ~ C - 7/20/92 (LI) A - 8/31/92 (LI) ~ (COMPLETE EXCEPT FOR'~ PLATFORM) ~ .~ P . 0' C - 6/8/92 A -4000M 11 Z l(NEED PRIORITY TO GET METERS INSTALLED)l 12/31/93 (ON SCHEDULE)
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START 1# DATE PROBLEM ~_...~ 1 EVIDENCE ~ 35 12/24/92 1 THE COOLING TOWERS ARE • REPEATED REPAIR COSTS 1 DETERIORATING ~ SINCE 1986 HAVE BEEN USED BEYOND EXPECTED LIFE -1 ~ 44 112/8/91 PRODUCT SLIPPING ON TRANSFER FREQUENCY OF PLUGS -~ BELTS ON ALL THREE LINES OBSERVATION OF OPERATORS 55 1 4/6/92 1 CURRENT PROCESS OPERATIONS - AMOUNT OF DOWNTIME II OF THE WEIGAND EVAP. SYSTEM - AMOUNT OF COST 1 v1 ARE NOT EFFECTIVE RESULTING ' IN UNRELIABLE OPERATIONS I~I~ 1 58 16/15/92 1 SIGNIFICENT UNEXPLAINED DIFFERENCES IN STEAM USAGE ~ 1 I EXISTS BETWEEN THE THREE LINES THAT MAY RESULT IN ENERGY INEFFICIENCIES. 1 59 6/15/92 1 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 PLUGGAGE MONTHLY STEAM USAGE TQMIS: L-I - 2,128,410 LBS/WK L-11 - 858,965 LBS/WK L-I1I 1,780,500 LBS/WK OFF STANDARD TIME ON PRE- HEAT FAN/COIL TEMPERATURE, PLUGGAGE & SLIME BUILD-UP ON COILS, MOISTURE ACCUMU- LATING ON COILS (C:C&I4) (ACTIVE) PRODUCTION DEPARTMENT CONTROL & IMPROVEMENT PLAN OBJECTIVE I TEAM MEMBERS TEAM LEADER/ DATE: 09/28/92 I (ACCOUNTABLE) PDCA TIME LINE 1~.. RESTORE COOLING TOWERS TO tj-Q~W+ vl RELIABLE OPERATING STATE 1 4.-iAN9K- EVAP L3 (ONE CELL) BRINE CHILLER L3 VACUUM SEAL PIT L1 / FIND AND INSTALL BELT THAT 4---j--pE8$- WILL REDUCE SLIPPAGE (EVALUATION OF RIBBED CONTINUING) BELT V/ IDENTIFY AND IMPLEMENT I-Q-ROIiANEA- IMPROVEMENTS IN PROCEDURES TO ENSURE CONSISTENT RELIABLE OPERATION OF THE WEIGAND VALIDATE THE EXISTING STEAM 8,-MERii USAGE TOM'S BY CONDUCTING A RESOURCE: ROUGH STEAM BALANCE TO -6-MTTCREFf DETERMINE IF AND WHERE ENERGY 4!r-tCSIC INEFFICIENCIES EXIST AND <I THEIR MAGNITUDE / REDUCE OFF STANDARD TIME ON TEMPERATURE BY 70% (ON SCHEDULE) ~- ra~e rs r•~ 1-&~f I P' 11 Q.-~+AxES. D- S 4_S41EEY6X-~ 1 I C • ~ ~ ~r -3oNE S^~ A ~niacaz - ~ y - o (NEW TIMELNE f P 2/24/92 D - 5/18/92 C - 7/26/92 A - 12/31/92 (ON SCHEDULE) 12/1/92 ~ (RETURN TO DO SEGMENT, 10/1/92) _0:-4AklNDtltS-- P - 7/92 D - 8/92 1 C - 10/92 ~ A • 12/92 (NEED TO BREAK INTO 3 PARTS/PROPOSALS 10/12/92) 4v-99NA#Eii- P - 6/30/92 / -c-r4A!lMegRS-- o -442- / C401-! IA 12M zs&vG4vzoz
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START tt DATE 1 61 6/15/92 I_I 1 63 16/29/92 1-1-1 1 64 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- I. SI2ED & RESULTS IN EXCESSIVE REPAIR COST & OPERATING PROBLEMS DUE TO CURRENT OPERATING MODE BIRD CENTRIFUGE MAINTENANCE REPAIR COSTS ARE 100 TIMES HIGHER THAN ALPHA LAVAL CENTRIFUGE AND CURRENTLY ARE CLOSE TO OPERATIONAL LIMITS NOT IN CONFORMANCE WITH PM SAFET)LPPI.,'S ~- -~' -I 1_ 66 19/16/92 1 PARK 500 CURRENTLY SHIPPING CONT. DR. BLADE REELS TO MASS & OREGON FOR REGRINDING RESULTING IN EXCESSIVE COST, LONG SHIPPING & TURN AROUND TIME, & SUBSTANDARD QUALITY I ON REGRINDS fC:C&14) EVIDENCE 1992 MONTHLY EXPENDITURE ANALYSIS-PURCHASE REQUESTS 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 (ACTIVE) PRODUCTION DEPARTMENT CONTROL & IMPROVEMENT PLAN 9--MERI1. P 7/6/92 ,IIr4AklBE{1&- D - 7/30/92 C • 9/10/92 A - 10/10/92 (NEED PARTS - NEW TIMELINE449244 TEAM LEADER/ OBJECTIVE TEAM MEMBERS (ACCOUNTABLE) PDCA TIME LINE .I I I 1 REDUCE PUMP DOWNTIME 1 6.-6LARJGi AND REPAIR COSTS I4.-L1EGK... -6°BltEtilR9~ V' DETERMINE NEEDED IMPROVEMENTS ~8~6Wqi*tf~ AND COSTS TO CURRENT L3 BROKE.I B,-OOl1Ai18N- 7 PUMPING TO ELIMINATE PUMP ' OPERATIONAL PROBLEMS & REDUCE I REPAIR COSTS TO S /YR 7 % O/t/. C/P 3 I A (TIMELINE-10/12/92) I UNITS ARE SECOND MOST IMPROVE LIQUOR CLEAN-UP AND ~~.. -.-.,...rl. 1I.aaLiAt••~1i I•r-"SffAXERT"' I P- 10/30/92 COSTLY REPAIR ITEM IN REDUCE MAINTENANCE REPAIR D-UMAHER F•~ D - VARIABLE REPAIR COST COSTS AT THE BIRD CENTRIFUGES I IC. EXPENSE IA STA-SIEVES BLIND OVER / ~? 6 flr' - SAFETY AUDIT /_.. 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 RESOLVE PROBLEMS NOTED BY I W. HAYES , A I U D I TI DIAUN~ RS I JENKIN J . NARRON I P- I D B ESTES A- T/9/92 I (NEW TIMELINE) I I I "-• LOCATE/DEVELOP ALTERNATE LOCAL -P-'OtlDtEY -fi--StfS1s- BE ~ L~AN ~ ~~i~/ I VENDORS TO REGRIND OUR CONT. I-,D~ &MRIt' ~W~fkY{•T.- PDA6 T 0'l /12i9Z ` ~ REELS AT OR BELOW CURRENT COSTI~R--BARC I I~?- 0aC FOR REGRINDING (E425-S500) I ID- ~I I I I~ CD{r / I I ~ ~n;l ~ I ~~ --~ ~'~zt,~ 4in~t. 9•:-iMARE'R'r- DATE: 09/28/92 P • ~~-30->,~ Dl;-~s_ I D - // - ? o- -? u9stUtzoz
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START # I DATE _I 67 19/18/92 _I 68 19/18/92 ~ PROBLEM EVIDENCE EQUIPMENT LOCK-OUT PRODUCTION DEPARTMENTAL ~ PROCEDURES/TRAINING DO NOT IMPLEMENTATION MOD II TOFA'S MEET THE EXPECTATIONS OF PRODUCTION MANAGEMENT ~ 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 1 PRODUCTION DEPARTMENT DOCU- MENTATION & TRAINING OF MSDS DOES NOT MEET PM, USA NOR AUDITOR EXPECTATIONS, RESULTING IN EMPLOYEES LACK OF UNDERSTANDING OF RESPONSI- BILITIES AND AN IMPROVEMENT FACTOR OF 50 (C:C&17) -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 - TOTAL - 28 (ACTIVE) PRODUCTION DEPARTMENT CONTROL & IMPROVEMENT PLAN DATE: 09/28/92 TEAM LEADER/ ~ OBJECTIVE TEAM MEMBERS (ACCOUNTABLE) PDCA TIME LINE IMPROVE METHOOOLOGY/SYSTEMS R~aRA~Lj~ Sr-QtltftT9M- FOR ENSURING EFFECTIVE 1-4.-NElQON- B~E3ff9-- I EQUIPMENT LOCKOUT IN PRODUC- iAN£i- ~ TION AREAS CORRECT EVACUATION PLANS AND 1-9--6NAP6- IMPROVE I-FACTOR BY 60% ~~~:=E•1NMFl~w' -FINAL TQFA RESULTS- TRAIN, THEN DOCUMENT CHARACTER- I I I- TRAINING FOR EACH EMPLOYEE; ISTICS JIMPIPERFIFACTOR IMPROVE I-FACTOR RATING BY A, 444L~.ialLS_ ~3:~ilcLAUGNI~•N~ .1,-~cNF~~ n -iti--1l~-ik•6- 4h:"K1Cr~ ~~y "'-----~•~~ -~R :-ilA6NEit-- ------------------------------------ 1 50% v ~• Clear Training 1 4 1 5 20 1 x I• Accurate Manuals 3 5 15 ~• Complete Manuals 2 5 10 ~ 0 ~• Manuals Available 1 5 5 to People - TOTAL - 50 Q. v9&vGLvz0z
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I 71 19/18/92 72 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 CREDIABILITY IN COST CONTROL EVIDENCE -FINAL TQFA RESULTS- CHARACTER- I I- ISTICS JIMPIPERFIFACTOR • - -----••--- ~. Effective Commun. 1 3 1 5 15 Appropriate Comnun.1 3 1 5 15 Cormwn. Understood 2 6 12 Timelinnes of 2 6 12 Communication I - TOTAL 54 PDMT MOD 11 1992 AUGUST COST 73 19/18/92 1 PRODUCTION SUPERVISION IS RECENT ACCIDENT UNFAMILIAR WITH EXPECTATIONS/ RECENT LOST TIME RESPONSIBILITIES THAT FORKLIFTI . LINGERING PROBLEMS OPERATORS RECEIVE DURING FORKLIFT TRAINING AT THE TRAINING CENTER 74 19/18/92 1 NO SYSTEM EXISTS TO ENSURE MAY, 1992 E,S,& H SAFETY AUDIT PRODUCTION DEPT PERSONNEL ARE TRAINED TO OPERATE MANLIFT EQUIPMENT ~ C:C8I7 s96Vs4Vz07; (ACTIVE) PRODUCTION DEPARTMENT CONTROL & IMPROVEMENT PLAN OBJECTIVE TEAM MEMBERS TEAM LEADER/ (ACCOUNTABLE) ~ DEVELOP SYSTEM TO COMMUNICATE -Pr-PH6tI6f- $~ REGULATORY INFORMATION IN A B,-t3FEALNSON 1~t.. I TIMELY MANNER; IMPROVE $rMA*6i CUSTOMER TOTAL I-FACTOR BY 55% DEVELOP SYSTEMS/ACCOUNTABIL- I $;-MERi$ ITIES TO ENSURE ENVIRONMENTAL 1-4,-dA61fi8N 1j;--S#yNp£RS- ABATEMENT EQUIPMENT IN PRO- ESOURCE - ~ DUCTION AREAS IS FUNCTIONING R-P~ PROPERLY AT ALL TIMES REDUCE YTD DEVIATIONS OR I 8r-@STE$ -d:MARReM PROVIDE EXPLANATIONS TO MEET I4-'0TES-- ROC EXPECTATIONS llBgfEN~ / ~6Ak1NBfRS` CONDUCT FORKL I F T FAM I L 1 AR 1• 44...kiJ.l. ~-B-fAtC ZATION TRAINING FOR I.g--inTEr PRODUCTION SUPERVISORS I ESTABLISH A SYSTEM TO ENSURE TRAINING IS ACCOMPLISHED AND DOCUMENTED FOR PRODUCTION PERSONNEL WHO ARE REQUIRED TO OPERATE MANLIFTS _DrAMP!"r- -O-r-MAi~ES-- DATE: 09/28/92 PDCA TIME LINE ACT • 12/31/92 ACT , 10/31/92 ACT - 11/15~ ~ 1
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(ACTIVE) PRODUCTION DEPARTMENT CONTROL & IMPROVEMENT PLAN DATE: 09/28/92 START # DATE -I 75 19/18/92 1 PROBLEM ~• EVIDENCE STATEMENTS OF PARTICIPANTS/ "RESPONSIBLES" UNFINISHED ASSIGNMENTS IN FULL COMPLIANCE WITH EH&S AUDIT FINDINGS/RECOMMENDATIONSI. PRODUCTION DEPARTMENT IS NOT SOLVING TEAMS BY d-9ti4SSr , .L1~C:3; ACT AUDIT (COMPANY POLICY) / ~I I 76 19/18/92 _ PRODUCTION DEPARTMENT IS NOT ~• NEW ASSIGNMENTS NOT PREVIOUSLY MADE 100% COMPLIANCE BY 12/31/92 ~ 7-•6t#88- IN FULL COMPLIANCE WITH S. (• UNFINISHED ASSIGNMENTS FROM EH&S V. MAY r$ DARRAHIS JOB PROCEDURE PROGRAMI CORRESPONDENCE (CO. POLICY & AUDIT UNFINISHED ASSIGNMENTS FROM HIGH- ,~ 8--~ RICHMOND EH&S REQUIREMENTS) RISK SURVEY 77 14/10/93 SPC SYSTEM REPORT DOCUMEN- -FINAL TQFA RESULTS- IMPROVE TOTAL I-FACTOR BY 4_Effe3" TATION HAS AN IMPROVEMENT CHARACTER- I ( 1- 50% AND ENSURE CAPABILITY FACTOR OF 50, RESULTING IN REDUCED CUSTOMER EFFECTIVENESS1 ISTICS JIMPIPERFIFACTOR I TO CONTINUOUSLY IMPROVE THE -----------------•------------------ I QUALITY OF THIS PRODUCT -B--SfEOFlGERS~ WHEN THIS PRODUCT IS USED . Accurate 1 3 1 5 15 Complete Clarity Legible ~ 3 ~ 5 ~ 15 ~ 2 ~ 5 10 2 ~ 5 10 TOTAL 50 I/, ~ ~ ACT • 12/31/92 lj ~ _T /, ~ -Y- rr; V / ( ~t,</yLf~ r7 78 19/18/92 1 1992 UNION CONTRACT CONSOLI- GENERAL LABORER PERSONNEL NOT ABLE DETERMINE TRAINING NEEDS AND -C.-#ARiSFlI. ~-9-NAtt- DATED THE FORKLIFT/CHECKER ANDI TO PERFORM FORKLIFT OPERATIONS IN CONDUCT TRAINING SO WE CAN ~9,0RM3- 4--ESTES-- GENERAL LABORER CLASSIFICATIONI SPECIFIC AREAS ABIDE BY INTENT OF UNION/ -0.--AMRb*-- ~ I SOME GENERAL LABORERS ARE NOT TRAINED TO PERFORM FORKLIFT AND/OR CHECKER ASSIGNMENTS IN ~ VARIOUS AREAS MANAGEMENT AGREEMENT TRNf,._GRBHP- 79 19/18/92 1 HOURLY PERFORMANCE LEVEL DOES LACK OF USE OF Q500 TOOLS/TECHNIQUES ~ I NOT MATCH TOTAL QUALITY NEEDS ~. LACK OF INVOLVEMENT ON PROBLEM TEAM LEADER/ OBJECTIVE TEAM MEMBERS (ACCOUNTABLE) PDCA TIME 100Y. COMPLIANCE MINIMIZE FUTURE FINDINGS/ISSUES ~• ~• 1. DEFINE BARRIERS & ELIMINATE .B'FSrES THEM ~if--tS-< ALLOW FOR DECISION MAKING ~"b dEN1t`i:T: AND RISK TAKING 0..-SAHMDER3- ( iNCREASE INVOLVEMENT / I °~-`z'z' / r i ,~ / ~Vtt/ ;. ACT - 12/31/92 sh--NAAReN- -.ACI-~-4f•fe V rl ~ ~%' •;I _ a~fli ~ ~ 99svs4vznz
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START I # DATE 1-1 80 19/18/92 PROBLEM SALARIED PERFORMANCE LEVEL DOES NOT MATCH TOTAL QUALITY NEEDS _~~ L 81 I9/18/92 1 CURRENT PRODUCTION DEPARTMENT SYSTEM FOR COVERAGE OF SHIFT SUPERVISOR VACANCIES IS IN CONFLICT WITH COMPANY I BUDGETARY GUIDELINES AND COMPENSATION POLICY RE: I ~ OVERTIME AND MAY RESULT IN A WORKLIFE/MORALE ISSUE AFFECTING JOB PERFORMANCE AFTER 1/1/93 C:C&17 4s9V6LVZnz EVIDENCE I L LACK OF USE OF Q500 TOOLS/TECHNIQUES1. LACK OF INVOLVEMENT ON PROBLEM SOLVING TEAMS NUMBER OF SHIFT SUPV. WORKWEEKS IN EXCESS OF 40 HOURS TODAY SHIFT SUPERVISOR INPUT (ACTIVE) PRODUCTION DEPARTMENT CONTROL & IMPROVEMENT PLAN TEAM LEADER/ OBJECTIVE TEAM MEMBERS (ACCOUNTABLE) DEFINE BARRIERS & ELIMINATE ~ 9-E6~E&' ~.l.-NARRAN-~ THEM , ..3, _.. ALLOW FOR DECISION MAKING AND RISK TAKING ~.A-SAUlDEES.. ~ INCREASE INVOLVEMENT . /- ~/ _ 1-8. E6fET DATE: 09/28/92 POCA TIME LINE ACT - 6/10/93 1

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