I fucking hate the disconnect with management/sales people and the Production line in just about any manufacturing job. I cut and build piston heads for fuckhuge engines that go in boats and those 2 story dump trucks in mines. its gotten so bad that all you can really do now is laugh at it. I actually started coming to work every day since last September expecting something to break, fuck up or otherwise go FUBAR that would leave some part of my line down for the day (prep, machining, measurement, building, shipment) and up until end of January, I was right 3/5 days of the week.
"Hey Billygoat, you know these 100 pound piston heads we cut that go anywhere from 10-16 per engine the size of a volkswagon beetle?"
"yeah."
"How many behind are we now?"
"I lost count march or april '18 at around 3000 units. Management won't give me numbers anymore"
"lol k"
Im not even joking with that figure by the way. Some chucklefuck in management or sales passed on an order that was physically impossible to complete. on top of that they ignored the issues with the machine we used at the time being an ancient piece of shit from 1990 which could get the equivalent of about 1 unit per hour and the numerous calls over the years to replace it because it would go FUBAR and production down multiple times a week. The machine ended up literally killing itself sometime between end of febuary to mid march last year. It said
FUCK YOU to my co worker and overtraveled so hard on startup it ripped out its own guts from the spindle, flooded the Hydraulic lines with cutting coolant, and cracked the radiator all in one go. we even had coolant spurt out of the Fill tank for hydraulic oil a good five feet from the fill point at the back of the machine. (supervisor ignored our reports on how fucked it was, forced the maintenance techs to force start the machine in that state. lol)
we were production down for a good month and a half which lost around 500 units of production during that time because they had NO plans to replace that machine or have any form of machine that could run the units. Thankfully I kept my job and still work for these chucklefucks, and during that month and a half they reprogrammed another machine halfway across the plant to cut the units. Still have to lug them two at a time by handcart back and forth from the old area to the machine and back however.
Cutting time on this second slightly less ancient machine is about 2 heads every hour and a half, though with various things like it also being a piece of shit, and dealing with basic tooling issues (replacing/adjusting cutting edges) it still clocks out at around 1 head per hour. with maybe an extra pair of heads on a good day.
while we do finally have a new state of the art machine being worked on and programmed to get these piston heads done, management still does not have a fucking clue about production capabilities.
In a shift meeting with us floor guys and management they do every quarter, the head guy in charge of the plant mentioned he wanted my line to eventually work up to about 54 heads cut per day. I audibly snorted at him and said that is not possible. I explained to him that running the machine 24/7 no stops for anything such as tool adjustment or the machine going tits up and expecting a constant supply of raw units (always in question) we can machine between 24 and 30 heads per day. that is the maximum capability of the machine.
in other note, when we do get this second brand new machine up and running, (which we do not yet know the production capabilities of, as in cycle time) if they want us to run both it and the old machine at the same time, we might e able to theoretically get 54 heads per day, but we will inevitably shut down and be unable to meet that demand anyway for multiple reasons.
we have 4 people on two shifts right now. we dont have the bodies to do everything as it currently is, let alone trying to tard wrangle both machines and everything else. We'd have to shut down within a few days because of either
A. no one to prep. cant get heads to the machine. shut down. current max production in readying heads for the machine is 12-16 in 10 hours. (Can ratchet it up close to 20 or more with two people tag teaming it though)
B. no one to build. Shut down because we have such a major surplus of heads that it would take days to push them all through to clear up the area.
C. lack of supply. we have had many times where our core supply is grossly inadequate to meet the current capabilities we have, just barely squeaking by at some points.
Hell, we could run into those issues anyway depending on how short the cycle time of this new machine is.
tl;dr, Force management and sales fucks to actually work with the areas for at least one week. then you wont get thousands of units behind.
How the fuck we still have this contract I will never know.