It was Ernie’s last week of work. My retirement present was to check the rooftop thermometer for him. It was a miserable experience. The access to the roof was on the other side of the plant. The roof was dark with no clear path to the thermometer. A couple times I had to cross a waist high wall. The wind was howling, the roof was slick, and the temperature was below zero. If I had slipped and couldn’t have gotten up, no one would have looked for me before frostbite set in. The last obstacle was a snow drift.
Incredibly, employees have been doing this task six times a day for years without complaining. A stairwell was present on the other side of the wall where the outside thermometer was located. A couple of steps and a door made checking the rooftop thermometer easy. Operators extended their breaks by fifteen minutes to check the rooftop thermometer. Since, a relief operator was needed for breaks and the new door made the long break unnecessary, the new door saved the company $6,000 per year in labor costs and it eliminated a safety hazard!
How could we have discovered this problem sooner?
Irritations are collected. For example, “I had to walk across the roof in a blizzard last night twice!”
Post these irritations above the suggestion box and solicit suggestions. Over four hundred people worked at the above mentioned factory. One of them would have discovered the need for another door.