I worked for a place once.. I was supposed to improve quality there. In my interview i was asked, "What would you do to get our staff to improve the quality of their output" I said, "Well, why do you blame them?? First thing i would do is to look at the quality of their work instructions, if they do not know EXACTLY what they are trying to acheive they will never get there.. Followed by. "you lot might be the best dart players in the world, if i took the numbers off the board though you will all be courgetteed..."
Instant job...
To start with, the workers hated me.. They decided that i was there to pick holes in what they did. I got a bunch of them together and said, "listen, i am here to see why you lot turn out ****, BUT, i know it is not you lot to blame, it is the **** work instructions and **** methods you have been given. i am here to help you, not pick holes in your work. After that, we all worked as a team, they loved me, and between us we did miracles..
Everyone is quick to blame the workers, the management think they know it all, but do not. They used to have to thermal spray shafts and the like, and bores of holes to a certain size, to obtain certain fits.
These were shafts and holes 18" in diameter sometimes.. They would spray a bit on, let it cool most of the day, spray a bit more. I said to the managers, why do you not just measure the temperature of the parts, do some calculations as you know the coefficient of expansion of the material, spray as required. and when it all cools down it will fit.
They seemed amazed, and were more amazed to see it worked. The workers even got me to teach them how to do it themselves. Massive increase in productivity and no more courgette ups..
One of the managers said to me "how did you know how to do that??" i said; "a mine of useless information i am!!" They said; "that is one of the most amazing things we have ever learnt. They were all PHD types in materials technology, i am a 5ww blacksmith [welder]
Difference is, i got sense...
john..