Follow the money. Before you do anything else, sit down and sketch out a budget for what it's going to cost to do everything the way that the instructor wants to see it done. Include both the capital cost of any modifications and extra equipment, the time it will take to write new procedures, and the cost of extra time which it will take to follow those procedures (and ensure they are followed) when introduced.
E-mail it to your plant manager, and cc the financial director, asking for authorisation for the budget required. I suspect the management view of the problem will change quite quickly. That said, an independent review of safety will almost always throw up some opportunities for change which will improve safety in your products and operations. Double insulation (particularly if the outer layer is a different colour to the inner layer) will make it easy to see if there is any damage on your current clamp-ready power cord. It would be an easy thing to do with some heatshrink sleeving. Reaching a compromise on the necessary changes is likely to be easier to agree than outright refusal to change, and reduces the likelihood of throwing the baby out with the bath water. Nick. At 13:56 -0400 30/7/09, Flavin, John wrote: >I like to know this group's experiences regarding the following, >which has been put into my lap to resolve. > <SNIP story of excruciating management idiocy> > >John D. Flavin >Teradata TCP Engineering >17095 Via del Campo >San Diego, CA 92127 >[email protected] >V: (858) 485-3874 >F: (213) 337-5432 > - This message is from the IEEE Product Safety Engineering Society emc-pstc discussion list. To post a message to the list, send your e-mail to <[email protected]> All emc-pstc postings are archived and searchable on the web at: http://www.ieeecommunities.org/emc-pstc Graphics (in well-used formats), large files, etc. can be posted to that URL. Website: http://www.ieee-pses.org/ Instructions: http://listserv.ieee.org/request/user-guide.html List rules: http://www.ieee-pses.org/listrules.html For help, send mail to the list administrators: Scott Douglas <[email protected]> Mike Cantwell <[email protected]> For policy questions, send mail to: Jim Bacher: <[email protected]> David Heald: <[email protected]>

