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
>

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