Tomorrow's Confrontation
by , 07-27-2008 at 09:33 PM (2761 Views)
I'm not sure why I'm bloging this. I don't usually mention my work too much. But this has been on my mind all weekend.
I've got a problem child on my project at work. My project, which I'm the manager and which is research and developement of a new approach to doing something highly technical (I never talk the specifics of what I do, sorry) has many subsystems, and and for the most part all the subsystems are doing well except for one. That is not unusual. Actually it's pretty good in my opinion if only one subsystem is a problem on a program. You never actually know going in, but you adjust and concentrate on what needs more attention. Part of the problem is that the vendor that makes the component for this problem subsystem is completely inexperienced and has absollutely no quality department or even understand the concept of quality. Their expertise is in making a large item which is made essentially one at a time, and so they have no concept of making multi copies with a consistent discipline. They were certainly a bad choice for this, but that's water under the bridge. We got a contract and we're stuck for now.
The reason we picked them was because of Bob. Bob is part of the team that designs this subsytem and has a really cozy relationship with this vendor. He has defended them and tried to cover up their inadequacies. But in addition, Bob is what I call a seat of the pants engineer. He jumps from one idea to another and then jumps to another and another. He's almost like a child with attention deficit disorder. Rather than sitting back and assessing the situation, assessing risks, and laying out a plan, and sticking to that plan, he'll impulsively jump from one idea to another. So not only do I have a vendor who really doesn't know how to make parts, I've got the guy looking over them who doesn't have good engineering skills.
So this subsystem was technically challenging and I've had to put some of my best engineers to concentrate on this task and look over Bob's shoulder. Actually more than look over his shoulder, they basically ran the task. They implemented quality checks at the vendor, worked the desgn changes that had to occur, and formulate a process that finally worked. Yes, it worked, but it put us six to eight months behind schedule. Over the course of that time we made 44 units to finally get to a point where 4 worked. And we went into our first big test at the end of June and all four worked. Enacting discipline and keen oversight (I had my good engineers at the vendor when they were making those last parts that worked) got us to a successful place.
But because of the slip we are now in a schedule crunch. Our next test is in September, and we have no more slack in the schedule. To start slipping now would involve going back to management and asking for more money, and in research and development there isn't any more money. So really now we have very little choice but to not slip schedule at any cost. The thing to do was to make these difficult units just like we made for the four that worked. Right? That's only common sense, make them exactly to the previous process. And that was a team decision, let's not incur any more risks because we can't afford a schedule slip.
Well the vendor wanted to simplify the process. There was a two stage molding process on making the unit that they wanted to consoldate into one. We had all agreed to make them with the two stage process for the next test and then once those are made they can investigate if a single mold process would work, when they had some breathing room in time. We couldn't risk it with the short schedule to September's test. I hope people are with me here, but again that's common sense and was agreed by all.
Well, Bob last week without consulting anyone else on the team gave the vendor the go ahead to make the parts with a single mold process. When I heard about it I really got upset. It was my engineers who are over looking Bob's work who told me. As it sunk in I really got angry. Lucky the process for now seems to have worked. But the more I thought about it, the more this burned inside me. I wrote the subsystem team an email, not mentioning any names that what occured signified a team out of control and that they were "damned lucky" that so far this had turned out right. Otherwise I would be seeking personnel changes to the team. Bob replied back that it was indeed him who gave the vendor the ok to make that change, and that it was the right thing to do because of all the problems we had in the past. Well, I replied back, again to the entire team, that he had assessed the difficuties correctly but the decision was completely incorrect, that the risks completely outweighed the benefit. And I went into the details of all the problems we still don't understand why and that to take risks was completely imprudent. But even more important than that, we had an agreed to plan and he willy nilly changed it on whim. And given this vendor's lack of discipline, I thought this a horrendous decision. I reiterated that if this happens again I would be seeking personnel changes, specifically him. I also carbon copied my quality department telling them i had a vendor without a quality department and a subteam without understanding of engineering discipline and that I needed to elevate this issue.
That was at the end of last week. That got Bob's attention. He called me to talk about this in person. We scheduled it for Monday, tomorrow, afternoon. I really don't know what Bob wants to talk about. I really doubt he's going to apologize. Bob is in his fifties, and frankly I have no idea how he got where he is. Actually he's a smart guy, but he has no discipline and doesn't work a lick unless he's forced to. I guess he's going to defend his decision. I have no idea what defense he can give, other than say it worked. But it's the fact that he went against the agreed to plan. I don't know what he's going to say, but I'm serious. I will kick him off my project if he does this again. I'm ready to bring up all his deficiencies. I'm not his supervisor, so it's not like I can fire him. But I am chartered to manage this project and I decide who works on it. I'll go to his bosses and tell them why he's a problem.
All I know is I need to control my temper. He's made me so mad over the course of this year a number of times that this is building.




