Best and/or worst examples of organizational communication

With my previous employer, I experienced the result of poor communication implemented in a production process. This resulted in a short circuit in the system, causing damages to the assembly and next higher assembly. As the Engineer assigned to investigate the problem, I found several errors within the product’s drawing and router sheet. The router did not required inspection on component orientation. The device had several components with reverse polarities and the power connector was reversely wired. The drawing showed ambiguity in the orientation of the positive and negative terminals. Thus, the item was wired with respect to the assembler’s understanding of the drawing.

When I finished my investigation, I discussed these issues with the Operations Manager for Manufacturing. I explained that the error was caused by inefficient documentation. During the assembly process, the router shall specify the correct orientation of each mechanical and physical component and it shall reference the adequate assembly document(s). During the inspection process, the router shall specify that the unit should be inspected per drawing and for the inspector to verify that all electrical and mechanical components meet correct orientation. Finally, prior to system test, a certified technician shall perform a continuity test of the power circuits per drawing and schematic. My solution was to improve the drawing and router so that all these steps are reflected in the common process. The result of our conversation concluded on the following statement “If we write all the necessary steps in the router and drawing then, we can just find people off street and pay them ten dollars an hour to perform the job”.

 

My understanding of this comment was “Have a crew of well paid workers that can perform “guess work” while we will employ Manufacturing Engineers that will develop bogus work instructions”.