The first shift in the packaging department reported for work around 7 a.m. After a brief meeting to go over the previous shift’s log, they set about the day’s work. But when the packaging line started running, they knew there was a big problem.
The bags were filling past their normal capacity and then tearing at the sealing station, dispersing powdered material into the air, covering the equipment. Before they could stop the line, at least 50 bags had to be scrapped, the material discarded, and production halted for the rest of the day.
The supervisor immediately called the crew together to find the problem. They found the bags were the wrong size, the equipment’s settings had been changed, and the warning light, which should have signaled a potential problem, was burned out. Frustrated, the supervisor blamed the crew for the disaster and threatened to dock their pay for the cost of the materials.