Great story. This is the kind of tale that illustrates how much chance enters into problem solving. I wonder what the odds are against all those conditions lining up perfectly just so the real problem could actually be perceived, let alone what Rod then figured out to solve it.
"The mechanical designers and fitters were still adamant that it was my problem because they had checked everything else already and nothing else was different from the machines that worked perfectly."
As a test engineer, whenever I was called to the line to try to figure out what was wrong with a test set I had built, I would always ask if the operator had run the "golden" units we used for calibration, to see if the test set was working properly and the data was accurate. The answer was often no, it never occurred to them when parts started failing that their process could have shifted - it MUST be something wrong with the test set!
The feeling of despair when a part you made might be causing a major problem in the field is a bad one. Proving your product is not at fault to the customeris not an easy task. Good job finding the fault under pressure.
In a crisis you can tell who is the most valuable employee- he's the one who isn't pointing fingers but has rolled up his sleeves and is going over schematics, checking out the equipment, and is not paying attention to the positioning going on in the rest of the group.
I admire the castigated engineer's diligence and sacrifice in getting to the site and doing whatever it took to get to the bottom of things. I don't think I would have prayed to Scotty, myself, as I have another God, but I guess Sotty sometimes answers prayers, too, it seems. :-)
Unfortunately, by not being in the political frey, it can sometimes cost one his job or advancement. Large companies can often lose site of the ones actually making things a success.
I was also impressed with the relationship that lasted 20 years. That is how real business is done!
Nancy, those "golden" parts have certainly been lifesavers for me on a few occasions. Several organizations do have a protocol in place to stop production whenever there are three failures in a row. That does make sense because if the process drifts why make bad parts, and if the tester has drifted then why ship parts of unknown quality. The operator would note the failed parametr and then run the golden parts while the production folks would check the line. Usually the problem was a process issue on the line.
The reality today is that even when you make a similar effort to solve a problem, you need to prepare to lose a contract or get fired, no matter if you show OTHER PEOPLE to be the cause of a failure or not!
That has been the reality for over 10 years now and my offspring is in the same type of situation where the Team Leader ( the position ) and the Team are blamed for the customer ignoring the requirements in a contract and getting predictable results. Even careful back- up notes doesn't change the management attitude.
The company is a major DR firm handling customer back up issues.
In my personal career, the last place I had a similar situation happen with a positive outcome was at Cray Research 25 years ago.
Now, the people behind the engineer sent to fix the problem get a threat and the Management types at the client company will FIRE the Engineer AFTER a problem gets fixed and report that that was the solution at the client company....I've run into that same situation 3 times in the last 25 years, so when I go out into the Real World to a customer site, I've already updated my resume.
For industrial control applications, or even a simple assembly line, that machine can go almost 24/7 without a break. But what happens when the task is a little more complex? That’s where the “smart” machine would come in. The smart machine is one that has some simple (or complex in some cases) processing capability to be able to adapt to changing conditions. Such machines are suited for a host of applications, including automotive, aerospace, defense, medical, computers and electronics, telecommunications, consumer goods, and so on. This discussion will examine what’s possible with smart machines, and what tradeoffs need to be made to implement such a solution.