Philip Morris
(Active) Production Department Control & Improvement Plan
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
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- Date Loaded
- 31 Jan 1999
- UCSF Legacy ID
- wou79e00
Document Images
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

(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..11 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)

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

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
Ir-"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

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% ~~~:=E1NMFl~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~-ik6- 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

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

(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-~-4ffe V
rl
~ ~%' ;I _ a~fli ~
~
99svs4vznz

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
