I had a fun day today at the packaging plant. First hour we ran the collating/overwrap system at 50 packages per minute. After a week of assembly, training and adjusting of everything, the system was finely in perfect tune with a flawless operation. Yielded 2,750 units in the first hour. We were set for a record 27,000 unit day.
Normal thru-put was 16,000 to 18,000 per ten hour day. This improvement would get us done with the contract just in the nick of time, today.
But then, the plant manager gave the operator the go ahead to go to 55 PPM. This over my heated objections. Within ten minutes the system crashed. Did they reset to 50PPM? Nope. They continued for hours to tune the line to the new velocity. Stressing the limitations of the equipment, and the personnel. Not to mention, making bad product and wasting time and materials.
I pleaded to go back to the sanity of a perfect speed within the abilities of the system components and the personal on it.
Nope. In fact, they removed me from the operation.
Whilst they did get it running better as the day progressed the never achieved the smooth effortless operation, that we had spent two days tuning in. The day finished, with everyone frustrated and tired, at 23,000 units. This despite the addition of a fifth person to keep up with the mess.
The plant manager justified it all by saying, "They need to learn to do it themselves!" "After all, you might die."
I wonder how much they learned that was useful.
This is a system I designed and built. Operated on this account for some 15 years. I sold the line when my company closed but kept this customer for the new owner. Never had an issue until the last time they ran the job. They screwed up bad.
On the last run before Christmas, we almost lost the account because of the "junk" these people packed. Which is why I was there making it run right.
Some never learn.
What a day!!
So, tonite, licking my wounds, I will be sourcing solace in a wee bit o' Scotch. And, with my head on a comforting lap with Crumpy.