August 6, 1996 in Corporate Headquarters America, jaws began dropping a few minutes before 8 a.m. At first the security guard just thought some Power Plant Giant had taken a wrong turn and showed up at Corporate Headquarters to ask for directions. When another one showed up, this time carrying his Playmate lunch box, hard hat on his head, and lip quivering looking for a handy spittoon, the men in their suits and women in their fine dresses began running for cover. That was the day eight Power Plant Men took over the floor in the building where the Corporate Engineers usually lived.
If you want to understand the shock that emanated throughout the building, just picture the following bunch showing up on your doorstep:
We had come from the four corners of the Oklahoma Electric Company Power Plant Kingdom and we were there in Oklahoma City because Corporate America needed our help! Two Power Plant Men from each of the main Power Plants were picked to help the company transition from the old Mainframe computer system to a new computer application called SAP. SAP was going to combine all of our computer needs into one big application that runs on the new computer network.
Ernst and Young was the consulting company that was helping us install and implement SAP at our company. The company began the implementation some time in March, and the big bang go live date was going to be January 1, 1997. According to Ernst and Young, this was a physical impossibility. There was no way we could convert all of our requirements into SAP realities in such a short time.
The Maintenance Module for SAP hadn’t even been fully developed. We were actually working with SAP to design the module. Our company had demonstrated how a Best In Class Maintenance process worked, and SAP was designing their module around our needs. Everyone insisted that our aggressive timeline was too unreasonable and would never be met.
The Electric Company in Central Oklahoma had one Ace up their sleeve (well, maybe more than one)… That was “Power Plant Men!” As I mentioned in last week’s post (See the post “Destruction of a Power Plant God“), I was told on Monday, August 5, to show up for work the following day in Oklahoma City to work for 10 weeks on an SAP project.
Mike Gibbs, a mechanic from our plant was going with me. Our task was to convert all the Power Plant parts in the Inventory system in searchable strings that had a limited number of characters. Mike Gibbs used to work in the warehouse, so he was a good candidate for knowing what odd parts actually were.
We were a cross-section of mechanics and electricians, and warehouse people. To give you an idea of how big our job was, we had over 100,000 different parts in the system. 75,000 of those parts were in the warehouse at the power plant where I worked. There were over 5,000 different types of Nuts and Bolts… just to give you an idea of the task ahead of us.
Ernst and Young said the task would take the eight regular employees four months to complete the task. The Electric Company said, “Power Plant Men can do it in 10 weeks.
We were able to use the office space used by all of the engineers because they all happened to be at the Coal-fired Power Plant in North Central Oklahoma where I normally worked because of the big explosion that destroyed part of the Turbine Generator room early Monday morning. While they packed up to begin the work of reconstruction, Mike and I packed up and headed to Oklahoma City.
Most of the “out-of-town” Power Plant Men stayed in hotels for the next 2 1/2 months, but Mike Gibbs and I decided that we couldn’t be away from our families that long, so we decided that we would drive back and forth to work each day from Stillwater, Oklahoma. This was about an hour drive with going to work traffic. We would meet in the parking lot of a Mexican Restaurant at the edge of town and take turns each day driving to Oklahoma City.
Normally, in an instance like this, we would get paid a mileage that was farther than if we drove to the plant and maybe even driving time to and from work each day, but when our Plant Manager Bill Green found out we were driving back and forth, he refused to pay us anything. He told us that it was far enough away that he would only pay for us to stay in a Hotel (which would have cost more than the mileage), he wouldn’t pay us mileage or even a per diem (which is a daily amount for expenses).
Bill Green knew that we were family men that wouldn’t want to be away from our families during the week if it was only an hour drive, so he played his card and said that we had to stay in a hotel, and he would pay the expense for that or he would pay nothing and we could drive back and forth all we wanted at our own expense, already knowing that we would rather wear our cars out and pay the extra gas each day to be with our families. I just thought this was pay back for me being so rotten all the time.
The first week I was there, I worked on converting the 5,000 different nuts, bolts and screws into cryptic search strings that all began with the three letter search word for bolt: BLT. If you wanted to search for a Bolt in the SAP inventory, you would know it begins with the letters BLT. This only made me hungry all week, because to me, a BLT was a sandwich. A mighty good one too, I may add.
After the first week, it was decided that having Power Plant Men roaming around between offices asking each other questions about parts was a hazard waiting to happen, so the engineer that was running our project Mark Romano had a special holding pen… um… I mean, cubicle built just for us. It was decided that we should all be together in what is called a “Bullpen Cube”. All nine of us.
There were nine, because a young Corporate executive had been assigned to help us with all things “Corporate”. His name is Kent Norris. He was lucky enough to stay behind to work with us, instead of having to go spend the next 2 1/2 months at our plant up north helping to repair the fire damage.
Well. I say lucky. Lucky for us, maybe not for him. After all, he was someone from “corporate” stuck in a cubicle with 8 rascally Power Plant Men that kept themselves motivated by playing practical jokes on whoever was willing to fall for them. Not ever having experienced the likes of us before, Kent was in for 2 1/2 months of relentless practical jokes being played at his expense.
I must say that we had a terrific time teasing poor Kent, but he was such fun and took our jokes so well, that we could only admire his resilience to bounce back and smile after we ran him ragged with one joke after the next. I will go into more detail about the jokes we played on Kent in a later post. For now, I am just mentioning our situation, so that you can get a picture of our situation.
Kent helped us with our expense reports each week, and showed us all the good places to eat lunch. He helped us adapt to corporate life. He even showed us how to use our temporary badges to badge in and out of the doors when we entered and left the building.
Mike Gibbs discovered a better way. He just put his badge in his wallet, and since he was tall enough, when he walked up to the badge reader, he just pressed the back pocket of his blue jeans against the badge reader, and voila! The door would open like magic! Onlookers were always staring at this strange assortment of men in blue jeans and tee shirts walking through the office building during lunch.
I tried to remember all the people that were there in the cube with us… I remember that I was there, and so was Mike Gibb from the coal-fired Power Plant in North Central Oklahoma.
Ken Scott, who was the Maintenance Superintendent at the Gas-fired Power Plant by Konawa, and David Roe who worked in the warehouse at that plant.
Doyle Fullen, an Electric Foreman from the coal fired plant in Muskogee, and Robert Christy, a mechanic also from that plant.
I believe Dan Hayer, the warehouse man, was there from the gas-fired plant in Harrah, Oklahoma on a small lake called Horseshoe Lake. I don’t remember who else was there from that plant. I remember seeing someone there, but I think he was a more of a quiet type and for some reason, his name has escaped me.
I was a sort of a computer programmer at this time, so I created small programs that would make our jobs easier. I created icons on the computers so that people didn’t have to log into the apps, and I created a couple of other small programs that just automated the monotonous manual steps that we would have to do over and over again as we plowed through the 100,000 different part descriptions.
After the first week, we had converted over 15,000 parts, and were on our way to meeting our goal.
So, how did we do? The Power Plant Men were able to convert all 100,000 parts in the inventory system to SAP in eight weeks! Two weeks ahead of schedule. This was typical for Power Plant Men, especially when you tell them it is impossible. This was another example of doing things that others said couldn’t be done.
We were all scheduled to go back to our home plants two weeks early when Mark Romano, our project manager came to our cube to give us the news… We had performed our job so well, they wanted to expand our scope. It seems that another department… I won’t mention which one, but their initials are T&D had been working on their measly 60,000 parts for the past 4 months and had only completed about 10,000 of them. They wanted to know if the Power Plant Men would be willing to give them a hand to convert the 50,000 parts in their inventory system the same way we did for Power Supply. Otherwise the go-live of January 1, would not be met since we were coming up to the end of September already.
Our Plant Managers had agreed that we could spend the next four weeks converting T&D’s parts as well, so of course, we agreed to stay on. I’m not sure if Corporate Headquarters was ever the same after that. Because we were able to stay on for the next four weeks, we were invited to an SAP banquet that we would have otherwise missed. We stood out like a sore thumb. I will write more about that banquet in a separate post as well as go into detail with some of the jokes that we played on Kent Norris.
Spending the 12 weeks in Corporate Headquarters was an important turning point in my career as a Power Plant Electrician. When we were in the bullpen cube, I was sitting in a chair where I could turn my head to the right and look out a window over the parking lot for the building. During the day I would watch people walking to-and-fro going about their business.
I had worked most of my adult life up to that point at a plant out in the country where when you climbed to the top of the 500 foot smoke stack and looked around, you could see fields and trees for 20 miles in any direction. Looking out that window at people made a big impression on me. Here I was sitting in an air conditioned office. No Coal Dust. No Fly Ash. No ear plugs to deafen the sound of steam shooting through the pipes turning the turbines. No 100 degrees in the summer. No freezing my fingers off in the winter. Just Power Plant Men quietly tapping on their computer keyboards, while they played jokes on Corporate Executive Kent. — This was the life.
I thought… things don’t get better than this. I was in computer heaven. Even though it was unconscious at the time, something stirred in me that thought… maybe… just maybe, I’m ready for a change…. I’ll wait and see what God wants me to do…
One of the phrases we would hear a lot at the coal-fired Power Plant in North Central Oklahoma was “Safety is Job Number One”. It’s true that this should be the case, but at times we found that safety was not the highest priority. It is easy to get caught up in the frenzy of a moment and Safety just seemed to take a second row seat to the job at hand.
Making Safety Job Number Two was usually unintentional, but sometimes on rare occasions, we found that it was quite deliberate. Not as a company policy, but due to a person’s need to exert their “Supervisory” Power over others. I mentioned one case in the post titled: “Power Plant Lock Out Tag Out, or Just Lock Out“.
During the summer of 1993, everyone at the plant learned about the Quality Process. I talked about this in the post: “A Chance for Power Plant Men to Show Their Quality“. I had joined the Action Team. This was a team of Power Plant Men that reviewed proposals turned in by the quality teams in order to determine if they had enough merit to be implemented. If they did, we would approve them. If we decided an idea was not appropriate enough to be implemented, we sent it back to the team that had written the proposal with an explanation why it was rejected.
Our team had turned in a proposal to create a Safety Task Force. One that would act like an Action Team similar to the formed for the Quality Process. It seemed like a logical progression. I was the main proponent of the Safety Task Force, but to tell you the truth, it wasn’t all my idea.
Not only had other members of our Quality Team mentioned forming a Safety Task Force, but so did our Electric Supervisor, Tom Gibson. He had called me to his office one day on the pretense of me getting in trouble…. I say that, because whenever he would call me on the gray phone and respond, “Kevin. I want to see you in my office right now.” that usually meant that I had stepped on someone’s toes and I was in for a dressing down…
— Was I the only one that had this experience? It seemed that way. But then, I was usually the one “pushing my bubble” (as Charles Foster would say). When I arrived at Tom’s office, he asked me if I would ask our team to create a proposal for a Safety Task Force. I told him that I’m sure we would. We had already talked about it a couple of times in our meetings.
I didn’t mind playing “Bad Cop” in the game of “Good Cop, Bad Cop”. That is, it never bothered me to be the one that pushed an unpopular issue that really needed pushing. Where someone else would follow-up as the “Good Cop” in a way that takes away the bitter taste I left as “Bad Cop” by proposing the same solution I proposed only with a more positive twist.
At the time, I figured that Tom Gibson was going to be “Good Cop” in this effort since he had pulled me aside and asked me to initiate the proposal. As it turned out, I ended up playing both Bad Cop and Good Cop this time. I played the Good Cop when Ron Kilman had met with me to discuss a new Safety Idea. The Behavior-Based Safety Process. See the Post: “ABC’s of Power Plant Safety“.
I proposed the Safety Task Force in a sort of “Bad Cop” negative manner. That is, I had pointed out how our current system was failing, and other negative approaches. When I explained how the Behavior-Based Safety Process works as “Good Cop”, Ron had told me to go ahead and form the Safety Task Force.
I asked for volunteers to join the Safety Task Force. After I received a list of people that wanted to be on the Task Force, I chose a good cross-section of different roles and teams from both Maintenance and Operations. I had lofty visions of telling them all about the Behavior-Based Safety Process, and then going down the road of implementing this process at the plant.
I didn’t realize that the Power Plant Men had different ideas about what a Safety Task Force should be doing. They weren’t really interested in trying out some new Safety “Program”. I tried explaining that this was a “Process” not a “Program”, just like the Quality Process. They weren’t buying it.
We had Ground Rules that we created the first day that kept me from ramming anything down their throats, so I went along with the team and listened to their ideas. It turned out that even though the Power Plant Men on the Safety Task Force didn’t want to hear about my “beloved” Behavior-Based Safety Process, they did have good ideas on how to improve safety at the plant.
We decided that we would ask for Safety Proposals just like the Quality Process did. It was felt that the Safety Task Force didn’t have any real “authority” and a lot of people at the plant thought that without the authority to really do anything, the task force was going to be an utter failure.
We decided that the best way to show that the Task Force was going to be a successful force of change toward a safer Power Plant, we would ask for ideas on how to improve the safety at the plant. When we did, we were overwhelmed by the response. Safety Concerns poured in from all over the plant.
At one point we had over 250 active safety ideas that we had decided were worth pursuing. The members of the team would investigate the ideas assigned to them and see what it would take to make the requested changes. Because of the overwhelming response, it didn’t make much sense taking all the approved requests to the Plant Manager. So, in many cases, we decided that a trouble ticket would be sufficient.
I posted the progress of all the active ideas each week on every official bulletin board in the plant. This way, everyone could follow the progress of all of the ideas. As they were successfully completed, they went on a list of Safety Improvements, that I would post next to the list of active proposals.
I think the members of the Safety Task Force might have been getting big heads because at first it appeared that we were quickly moving through our list of plant Safety Improvements. A lot of the improvements were related to fixing something that was broken that was causing a work area to be unsafe. I say, some of us were developing a “big head” because, well, that was what had happened to me. Because of this, I lost an important perspective, or a view of the ‘Big Picture”.
I’ll give you an example that illustrates the “conundrum” that had developed.
We had created some trouble tickets to fix some pieces of equipment, and walkways, etc, that posed a safety risk. After several weeks of tracking their progress, we found that the trouble tickets were being ignored. It seemed that this came on all of the sudden. When we had first started the task force, many of our trouble tickets were being given a high priority, and now, we were not able to succeed in having even one trouble ticket completed in a week.
After going for two weeks without one of the trouble tickets being worked on, I went to Ron Kilman, the Plant Manager to see if we could have some of his “Top Down” support. To my surprise, he gave me the exact same advice that our Principal, Sister Francis gave our Eighth Grade class at Sacred Heart School in Columbia, Missouri when we ran to her with our problems.
Ok. Side Story:
Three times when I was in the eighth grade, our class asked Sister Francis to meet with us because we had an “issue” with someone. One was a teacher. We had a personal issue with the way she conducted herself in the class. Another was a boy in the 7th grade, and the fact that we didn’t want him to go with us on our yearly class trip because he was too disruptive. The third was a general discontent with some of the boys in the 5th and 6th grade because of their “5th and 6th grade” behavior.
In each case, Sister Francis told us the same thing (well almost the same thing). In the first two cases, she told us we had to handle them ourselves. We had to meet with the teacher and explain our problem and how we wanted her to change. We also had to meet with the boy in the seventh grade and personally tell him why we weren’t going to let him go on our trip. In each case it was awkward, but we did it.
In the case of the 5th and 6th graders, Sister Francis just said, “When you were in the 5th grade, if you acted the way these 5th graders acted to an eighth grader, what would happen? Well. Deal with this as you see fit. We all knew what she meant. When we were in the fifth grade, if we treated the eighth graders the way these guys treated us, they would have knocked us silly.
So, the next morning when I was approached by a fifth grader displaying the disrespectful behavior, I gave him a warning. When my warning was greeted with more “disrespect”, I did just what an eighth grader would have done when I was a fifth grader. I pushed him down the stairs. — Not hard. He didn’t tumble over or anything, but he ran straight to Sister Francis and told her what I had done.
Sister Francis came up to our room and told me to go to the principal’s office. — We only had 14 people in the Eighth Grade, so it wasn’t hard to find me. I protested that I was only doing what she authorized us to do the previous day. She agreed, but then she also explained that she had to respond the same way she would have responded to the eighth graders three years earlier if they had done the same thing.
I could tell by her expression, that my “punishment” was only symbolic. From that day on, the 5th and 6th graders that had been plaguing our class were no longer in the mood to bother us. We had gained their respect.
End of Side Story.
So, what did Ron Kilman tell me? He told me that if we were going to be a successful Safety Task Force, then we would need the cooperation of Ken Scott. Ken was the Supervisor of the Maintenance Shop and the one person that had been holding onto our trouble tickets. Ron said, “You will have to work this out with Ken yourself.” — Flashes of Ron Kilman wearing a black nun’s robe flashed through my head, and suddenly I felt my knuckles become soar as if they had been hit by a ruler. — No, I’m not going to draw you a picture.
So, we did what would have made Sister Francis proud. We asked Ken Scott to meet with us to discuss our “issue”. We pointed out to him that the trouble tickets we had submitted were safety issues and should have a higher priority. We also pointed out that we had not had one safety related trouble ticket completed in almost three weeks.
Then it was Ken’s turn…. He said, “Just because you say that something is a safety issue doesn’t make it one. Some of the trouble tickets submitted were to fix things that have been broken for years. I don’t think they are related to safety. I think people are using the safety task force to push things that they have wanted for a long time, and are just using “safety” as a way to raise the priority. Some of these ideas are costly. Some would take a lot of effort to complete and we have our normal tickets to keep the plant running.” — Well, at least when Ken stopped talking we knew exactly where he stood. He had laid out his concerns plain and clear.
The Safety Task Force members used some of the tools we had learned during the Quality Process, and asked the next question…. So, how do we resolve this issue? Ken said that he would like to be consulted on the ideas before a trouble ticket is created to see if it would be an appropriate route to take.
It was obvious now that we had been stepping all over Ken’s Toes and our “demands” had just made it worse. Ken felt like we had been trying to shove work down his throat and he put a stop to it. After hearing his side of the story, we all agreed that we would be glad to include Ken in all the safety issues that we thought would require a trouble ticket.
From that point, we had much more cooperation between Ken Scott and the Safety Task Force. Ken really wasn’t a problem at all when it came down to it. The way we had approached the situation was the real issue. Once we realized that, we could change our process to make it more positive.
This worked well with Ken, because he was forthright with us, and had spoken his mind clearly when we asked. This didn’t work with everyone of the people that pushed back. We had one person when we asked him if he could explain why he was blocking all our attempts to make changes, his only reply was “Because I am the barrier! I don’t have to tell you why!” That is another story. I’m not even sure that story is worth telling. I know that at least one person that reads this blog regularly knows who I am referring to, because he was in the room when this guy said that…. He can leave a comment if he would like….