Wow! 30+ replies in 10 days. We members of the Cove are seriously concerned for your personal safety, LumaraC.
As a consultant of long experience, I see many danger flags surrounding LumaraC's situation.
Deming was right, of course, in assigning most of the blame for things gone wrong to management. Sometimes, the reason is greed. Sometimes, ignorance. Most often, though, it is a combination of greed and ignorance, coupled with complete disregard for the safety and well-being of employees.
In a well-run organization, some form of FMEA (Failure Mode and Effects Analysis) would take place. Probable recommendations arising from such a risk analysis would include those already mentioned in previous posts. Most important, though, would be one which says, "Do not accept orders beyond your organization's capacity."
Calculating that capacity must take into account a regular repair/replacement/maintenance schedule as well as setting up a fund for buying more machines or more efficient machines to increase capacity. Along with that would be arranging more space to put the machines, more lines of credit to finance the machines and employees to run the machines, and more money to buy the raw materials to feed the machines.
Where does LumaraC fit into this scenario? In his note to the managers, he has to have the courage to tell the truth:
"I have consulted experts regarding this matter. They advise the organization is taking huge financial risk of disaster by forcing machines to work beyond design capacity that WHEN (not IF) they break down, it will be much more expensive to repair or replace them and we may risk losing any disappointed customers forever. We need to schedule regular downtime for maintenance and budget time for unexpected repairs."
As a consultant of long experience, I see many danger flags surrounding LumaraC's situation.
Deming was right, of course, in assigning most of the blame for things gone wrong to management. Sometimes, the reason is greed. Sometimes, ignorance. Most often, though, it is a combination of greed and ignorance, coupled with complete disregard for the safety and well-being of employees.
In a well-run organization, some form of FMEA (Failure Mode and Effects Analysis) would take place. Probable recommendations arising from such a risk analysis would include those already mentioned in previous posts. Most important, though, would be one which says, "Do not accept orders beyond your organization's capacity."
Calculating that capacity must take into account a regular repair/replacement/maintenance schedule as well as setting up a fund for buying more machines or more efficient machines to increase capacity. Along with that would be arranging more space to put the machines, more lines of credit to finance the machines and employees to run the machines, and more money to buy the raw materials to feed the machines.
Where does LumaraC fit into this scenario? In his note to the managers, he has to have the courage to tell the truth:
"I have consulted experts regarding this matter. They advise the organization is taking huge financial risk of disaster by forcing machines to work beyond design capacity that WHEN (not IF) they break down, it will be much more expensive to repair or replace them and we may risk losing any disappointed customers forever. We need to schedule regular downtime for maintenance and budget time for unexpected repairs."
