OT--Sometimes simple solutions are overlooked !

Jiles

Well-known Member
This is a little long, but good.
Sounds like what our Government might do!

A toothpaste factory had a problem. They sometimes shipped empty boxes without the tube of toothpaste inside. This challenged their perceived quality with the buyers and distributors. Understanding how important the relationship with them was, the CEO of the company assembled all of his top people. They decided to hire an external engineering company to solve their empty boxes problem. The project followed the usual process: budget and project sponsor allocated, RFP, and third-parties selected.
Six months (and $8 million) later they had a fantastic solutution - on time, on budget, and high quality. Everyone in the project was pleased.

They solved the problem by using a high-tech precision scale that would sound a bell and flash lights whenever a toothpaste box weighed less than it should. The line would stop, someone would walk over, remove the defective box, and then press another button to re-start the line. As a result of the new package monitoring process, no empty boxes were being shipped out of the factory.

With no more customer complaints, the CEO felt the $8 million was well spent. At the end of the first month, he reviewed the line statistics report and discovered the number of empty boxes picked up by the scale in the first week was consistent with projections, however, the next three weeks were zero! The estimated rate should have been at least a dozen boxes a day. He had the engineers check the equipment and they verified the report as accurate.

Puzzled, the CEO travelled down to the factory, viewed the part of the line where the precision scale was installed, and observed that just ahead of the new $8 million dollar solution sat a $20 desk fan blowing the empty boxes off the belt and into a bin. He asked the line supervisor what that was about.

"Oh, that," the supervisor replied,"Bert, the kid from maintenance, put it there because he was tired of walking over, removing the box and re-starting the line every time the bloody bell rang.
 
Been there, done that--only we'd have spent $16 million trying to figure out why we had 12 empty boxes a day instead of only $8 million detecting and throwing away the bad ones. Course you're hearing this from an old manufacturing engineer, not a quality guru.
 
Know of a national bakery, (now defunct), that tried to replace 8-10 minimum wage donut packers with an automated packaging machine. Machine went through 4 iterations over 3 years, was finally chucked in a scrap dumpster (literally) and 8-10 human donut packers were hired. Best numbers I could get showed around 6 million in the machine, not counting tons of wasted product and man hours re-engineering/repairing/modifying it.
 
I read about a maintenance man for GM back in the 80s, he got a huge bonus for telling the boss if they turned a piece of steel side ways, they could cut two hoods from one sheet of steel instead of one. (he pushed a broom for them)
 

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