Brad was a maintenance electrician at a plastics plant. The plant had designated repair techs, based on the idea that pulling someone off a maintenance job is asking for failures in the future. Brad kept noting odd problems with equipment. For example, the plug-in cabling connectors in various electronics were not fully engaged. He’d often find detritus and grease smudges in the cabinets, and dirt in moving parts.
He reported this to Mike, the electrical maintenance manager. At first, Mike was also baffled.
One day while Brad was performing the quarterly preventive maintenance on a production line drive system, he felt a tap on his shoulder. Mike had something to show him.
Jeff, a repair tech, had responded to a downtime call. As Brad and Mike rounded the corner, they saw Jeff wipe his hands on his coveralls. “Doesn’t he know how to use a shop towel?” Brad asked. They both noticed parts sitting directly on the floor.
Jeff had the technical chops, but he did not understand good workmanship, good work practices, or good work hygiene. Subsequent investigation proved Jeff’s lack of training in the “softer” skills had caused downtime.
