Follow Up, Engineers, Do I Leave my Conscience at the Door?

Hello all, (This is a true long winded story)

I posed the question on 4-1-09 and I received a fabulous number of responses. It was a growing experience for me and I would like to share the outcome with you as light- heartedly as possible.

The background is as follows: I worked as a Sr. Project engineer for an injection molding company supplying to NUMMI (Joint Toyota and GM venture manufacturing Corolla and VIBE.) I had a 'Geppetto' attack. " always let your conscience be your guide"!

I was torn between unveiling a design for a new machine which I figured would eliminate 4 production jobs or hiding the possible improvements to keep people from the unemployment line

Actual facts: 1. A scaled down project was completed by making one machine for evaluation to justify the implementation of 4 total machines. It was a mechanical success and the takt time was improved by the forecast amount.

2. Things quickly went south after my post. The economic downturn forced GM to stop the Vibe 2 years into a 5 year contract( last day was Aug 14). Toyota threatens to pull out of NUMMI and close the doors and say they will confirm their intentions by Aug 31.

3. Here is the meat of the whole thing and an unfolding tragedy of human behaviour when threatened, whether your a $9.50 per hr. or a $47.00 per hr person.

Men's bravado V women's survival instincts. Assembly team is 7 strong comprising 3 guys and 4 women + 1 women Team Lead. The first 1/2 hour of day 1; I show all what the new gadget does, I pick a 'volunteer' and see how they take to it. As a Team they are excited. The guys are shy, women volunteer each other 'till all women and no guys have tried to run the machine. Then the guys bluster and blunder thru with bravado to try to out do the women. That is their focus. I left them to play for 2-3 hrs and then let the Mfg Engineers take over with the stop watches 'on'.

Now guys volunteer first, they are scary fast. (Original line takt time 21.5 sec per part over 8,140 pts per shift. My projected saving was a reduction to 18 sec, I have a 2 sec cushion built in.) The guys tease each other, "Is that it bro"? recording an average 16.4 sec each for 200 parts each.

The women show up slower in the time tests than any of them had performed in the introductory play time. I realized immediately that I was in trouble, something was at play here and it was not the machines capability.

The women, they were quiet, compared to the morning session and not impressed with the smell of testosterone. They averaged 20.4 sec each part. I had seen as low as 14.5 from a lady that could not beat 23 seconds during afternoon or in subsequent timing.

3pm break day 1: Ding! ding! the normal banter between the women and men is now a menacing quiet. The bulb flickers in one guys noggin and wow, the guys whisper, they are feeling duped and embarrassed.

There is no doubt in my mind what the capability of the machine would be in normal times, based on the intro timing and excitement of the group. I was able to address all the quirky hic-cups and handed over the machine to Manufacturing a week later Toyota upper management came to assess it and it's output, to see if it met my projections and whether I used their SPCA training in the development and introduction process.

Our company lost out on being a prestigious World supplier at SOP (start of production) in 2008 as they could not produce fast enough. There were all kinds of accolades and thoughts of World Supplier prestige now=more business.

My involvement made me sick and I tried to give it a wide berth after seeing the reaction from the clever operators on the floor.

I noticed the machine sitting idle on a daily basis. 'Jose or Maria' could not get it working. It had every ailment but swine flu. It started with subtle disconnections of the sensors, then ruptured air lines then logic problems and air valves being closed or 'dirty'.

A month passed, I was asked daily by enthusiastic managers upper +lower and guys who just loved the speed of the machine, why it was not being used.

Finally at the end of month 2 the Owner approached me and demanded to know why it was idle, as he was being urged to submit proposals to Toyota at the highest level. What could I say! I turned it over 2 months ago? NO! He knew me better, as a tenacious guy who does not give up readily. He read me like a book without my saying a word he sent a memo to MFG, "run it every day, hail rain or snow" (in California).

The poor operators ran out of excuses - the machine was as fast as they were, period. The guys stupid need for speed could not be tamed even with young families to feed. The women are smarter, they have dragged 2 -3 months extra employment from the company and are not about to give in like the guys. (Toyota qualified the product from the machine- in one week, a big step.)

What can the women do, they are being squeezed by the guys on the team and management. There was no place far enough away from this little beast, where I could take refuge. Upper management were convincing themselves that 6 machines was the right number. I would not budge on the price ( independent contractor that I am). Heeding the Local newscast I felt it was all coming to a screeching halt and hated to tell my wife that I might earn an extra $48K for the next 6 new machines.

Friday--- 1 week ago. "Tinker can you join me in my office please". ( Boss and HR) Owner says to cut 33% from ENG dept. Sorry! Johnny 1 and 2 have 20 yr and 12 yr seniority over your 3.

All staff salaries were cut 20% the day before. The Toolroom Supe' is retiring in 2 weeks and seeing as you have your own shop you would fit right in------ pay is $30k less than you have now-----how do you feel, will ya take it, willya-willya! "If you need an instant answer" -- (----you!). You have 10 mins (HR). Boss, No! No! tell us Monday. Keep it under your hat.

I feel like "dead man walking" . I tried to make sense of it as I take the walk of shame and the 'why me's are erupting from my stomach. I slither back to my desk trying to be invisible, I think, how can I clear it without raising questions? Am I really about to leave for ever, or go to the Toolroom (demoted).

It was the middle of the am. We went to lunch. HR told me my boss was sick to his stomach and left for the day at 1:30.

I skidaddled by 2:30 and my 2 college student boys wondered why Dad was home so early. Mom was still at school. 'Mom cried quietly', later.

I explained that it was seniority etc and I would run the Toolrom temporarily. On Mon, I told my Boss I would accept the lifeline and gladly do it. I felt like crying inside but no body was going to see that. I remained my jolly self and people were shocked to hear that I had been fired and rehired -- they still are. I was assured, ( as one can be), that in the event of a full NUMMI closure I would now, be needed 'till the end as production is at 960 Corollas a day and tools have to be maintained.

Summation: and the inevitable question.

The guys in the toolroom accepted me with open arms- we could set this and that PM stuff up on a new software that I had championed and make all these improvements. They were enthusiastic and excited. My colleagues were unusually sensitive.

Bad news came thru bush telegraph at 1pm today. It is final--- Toyota is closing NUMMI.

I was working split shift to acquaint myself with personnel on both shifts, on a level that I was not used to. On hearing the news, their sense of rage was palpable, the utterances of, why should we give a ---- now, were flying.

I sat them down and said that your in a better shape than most, as you will be here 'till they close the plant, if you have not found another job.

I urged then to take the time to process the news. I have asked that they come back with a vow that they will not send any mold out to the floor that is not as good as they can make it and that they show the utmost pride in their workmanship to the end, regardless of how they feel.

I felt like I was hovering over the Titanic urging the orchestra to keep playing to soothe the passengers bound for the frigid Atlantic waters.

I then put on a one man play. I stood erect and harkened to my bosses call of Fri last. " we have to let ya go, etc, but we can offer you a 30% cut in pay if you manage the Toolrom as a working Supe." . I hunched one shoulder and walked away.

This Friday I will be called into the office. " we have to let ya go, etc but we can offer you acut of 30% if you manage the maintence Dept. (its a 40' container out the back that they make wicked tables and things for MFG). I hunch my shoulder more and shrink 6 inches.

The following Friday I will be called into the office. " we have to letya go, etc but we can offer you a 30% cut and you can manage the one janitor left out of 4".

I asked can you imagine being fired 3 times in 2 weeks, having never benn laid off ever?

I am almost on the ground and totally hunched over when I looked up to see the reaction of the troops. They were cracking up and the rest of the day seemed much lighter.

Here it is. Should you urge somebody who is facing imminent job loss to keep working hard? How can you justify it and what would you say to ease the pain.

I know it is not the company's fault and also know that they will leave with what they came in with--- nothing, but are richer for the experience.