Lifting Hoist

The day after the last note from Gajanan to his crew, he came over to my desk and pulled me from what I was doing. We had a table banging session. Well, actually, he was the one banging the table.

He was demanding sorting before materials got to the floor, and kept saying "I don't care! It's not my problem! You call him now and tell him I'll not take any of this!". I had to listen and retort, "Yes, but we need to be reasonable. The reality is that there's no way we could check on it in storage." After a 10 min persuasion exercise, we both came to a compromise. I'll call the supplier, and get their tech guys when we run our trial, and he'll keep off my back.

Finally, before I left the lab:
Me: "Go easy on me. You know me better than that."
Gajanan: "Exactly. It's because I know what you can do."

I do not know whether to punch him or thank him.

It seems that one by one, PTs LPTs, MTLs are coming forward with feedbacks, issues, developmental ideas, product ideas to me. It's encouraging. But many still do not want to accept 2 things:
1) I'm there for less than 3 months;
2) I'm not a chemist by training

Many of them say nice things, like "The previous guy never came in on thhe night shift", "The previous guy didn't do the things you did", "Finally, our feedback is taken seriously!", those sorta things.

It's endearing to have even the foreign coach tell me this. Alhamdulliah! Whatever I do is with His Strength, Guidance & Wisdom! Insya Allah, I do hope that I can push forward more intensely in a short period of time to get things going.

Honestly, I love the challenge. But I'm afraid of the pressure. The pressure's getting higher for me. With this improvement in feedback and information collection, everyone's expectation's getting higher. The speed of delivery needs to be tuned so that materials move faster as well. And many assume, just because I sit in the lab together with Lito, I'm a researcher as well. Lito has been with KC for close to 30 years, since he was 19! I'm nowhere near there.

Insya Allah, I will show Allah's Virtues to my colleagues. And continue to Gain His Strength & all things good in my work. Please bless me Allah. Please bless Suraya as well in her studies & work. We Love You!!!

jahwsl
1125
17 Feb 07'
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From: Nadgouda, Gajanan
Sent: Thursday, February 15, 2007 5:33 PM
To: Nah, Alex; Krishnan, Mathanan; Mohamed, Muiz; Lim, TienChin
Cc: Wong, Jeremy Ah
Subject: RE: Improvement of Ear Material Diameter

Hi Lim and Mathanan,

Its nice to see some one praising you guys keep up the good work. We will take the guide lines given by Jeremy to get some good numbers.

Regards

Gajanan

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From: Wong, Jeremy Ah
Sent: Thursday, February 15, 2007 2:27 PM
To: Nadgouda, Gajanan
Subject: FW: Improvement of Ear Material Diameter
Importance: High

It only takes a spark, to get a fire going.

A simple request on managing the situation turns out to be something that we could counter with increased productivity and efficiency. I am encouraged that one by one, your LPTs are making the effort to seek change & improvement. Lim & Mathan are good examples. I am sure the rest are as well, only that I do not see them as often enough to speak with them.

Your team takes your instruction well in managing raw material. However, I would like for you to know that for outer cover folds resulting in rejection, your LPTs can reject the roll without a second trial if:

1) There is less than half of a roll remaining;
2) A good run is experienced;
3) Your target for the day has not been met and production is the primary initiative.

For those reasons, your LPTs need not be subjected to reload materials twice – although prudence is encouraged. And our practiced prudence is what gives the supplier confidence in us to reject materials on your LPTs decision. Please see excerpt from Dae Myung’s note to me:

Quote

“By the way, as once a material is rejected, your Lead Process Technicians can be authorised for it’s disposal. No problem..but need to make a memo such as lot no. quantites and so on for my reference.” Unquote

All we need is constant fresh supplies that are ready to be spliced.
It’s precisely why we’re working so hard to justify rejecting material so that your crew can focus on producing volume!!! If in doubt, put the material aside and use a new roll. And try not to take my job away from me.

jw

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From: Woo, Lionel
Sent: Thursday, February 15, 2007 7:21 AM
To: Nadgouda, Gajanan
Cc: Ferng, Bernard ; Wong, Jeremy Ah ; Estrella, Creselito; Santoso, Dewi ; Kee, TeckHua ; Ramasamy, Marimuthu ; Lim, TienChin ; Woo, Lionel ; Chan, YeatHong
Subject: RE: Improvement of Ear Material Diameter
Importance: High

Gajanan Boss,

Please have a short discussion with me on this modi. Give me your plan and expected spec for this modi.

Thanks

Lionel

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From: Nadgouda, Gajanan
Sent: Wednesday, February 14, 2007 5:17 PM
To: Woo, Lionel
Cc: Ferng, Bernard ; Wong, Jeremy Ah ; Estrella, Creselito ; Santoso, Dewi ; Kee, TeckHua ; Ramasamy, Marimuthu ; Lim, TienChin
Subject: RE: Improvement of Ear Material Diameter

Hi Bernard,

It’s a good suggestion to go for bigger roll diameters and modify our lifting device.

Lionel,

Boss can we have your attention to these hoist lifting devices and get it modified.

Thanks and regards

Gajanan N N

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From: Ferng, Bernard
Sent: Wednesday, February 14, 2007 1:45 PM
To: Wong, Jeremy Ah ; Estrella, Creselito ; Santoso, Dewi ; Kee, TeckHua ; Nadgouda, Gajanan ; Ramasamy, Marimuthu ; Lim, TienChin
Subject: RE: Improvement of Ear Material Diameter

Hi all,

What does it take to modify the guard and loading instead.

We would like to increase the roll diameter and not decrease. An increased to about 1100mm would be good as a start and 1150mm at the next phase.

Thanks.

Bernard

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From: Wong, Jeremy Ah
Sent: Wednesday, February 14, 2007 1:21 PM
To: Estrella, Creselito ; Santoso, Dewi ; Kee, TeckHua ; Nadgouda, Gajanan ; Ramasamy, Marimuthu ; Lim, TienChin
Cc: Ferng , Bernard
Subject: Improvement of Ear Material Diameter

Lito,

Currently, Ear Material (SAP: 25200402, Total Area 3,384m2) from Toray Saehan arrives in roll diameters of about 1,004 mm. As you can see from the attached pictures, these rolls are unable to fit squarely on the mechanical material handler before they are hoisted and loaded on to the machine spindle.

Picture Ear_01 & 03 shows the guard hitting the top of the loaded roll;
Picture Ear_05 & 06 shows the mechanical material handler not being able to full fit into the core because of the obstruction from the guard;
Picture Ear_02 & 08 shows the differential between the roll & mechanical material handler.

These pictures are taken from ST02 & ST01.

There is not much of a choice now but to fit the rolls as tightly as possible onto the machine’s spindle. This may also cause creasing and tears in the material. A safety hazard as well if the LPT or PT were to remove the portion of the damaged area when it is loaded onto the machine by hand. The only other solution would be to remove the materials till they fit into the mechanical material handling’s spindle and clears the top guard, which will result in waste.

Our rolls currently come in at 3,384 m2 ~ 1,004mm diameter. Feedback is to improve fit to allow for approximately 990mm in diameter. @ 990mm diameter, approximate square area would be 3,337m2, which is 48m2 lesser than the current. If you are agreeable to the modification, I would communicate with Chang on confirming the actual area of the material (it should be directly proportionate), the possibility of reducing roll diameter, as well as prep for trials.

For your approval, please. Thank you.

Dewi,

Would we still be able to satisfy our consumption/buying requirements if each roll is at 3,337 m2 instead of 3,384 m2 (assuming the reduction of roll diameter is directly proportionate to what we are receiving now). Truly appreciate it.

MTLs,

Unlike the issue the difficulty of fitting LST cores (we tested all aspects of the materials to be in spec as well as confirmed with the supplier on material integrity, therefore, we suspect the wet weather late last year & early this year to be the possible cause of the ill-fit), this situation is common for all three lines.

RM has no qualms to gather, review feedback, and possibly effect changes, so long it is a reasonable demand (little or no compromise on cost or safety), as in this case it would very much be. And as long as it is not expected to be done overnight (there are material specs to be reviewed, communication with suppliers, logistical & possible legal issues, etc.) All contributions & suggestions from all personnel would be taken seriously and responded accordingly.

As always, thanking you.

Lim,

Thank you for your feedback. We look forward to more of you/your crew’s feedback to effectively achieve our primary initiative.

Wishing all a blessed, safe & prosperous Chinese New Year!

jw