Cost of line shutdown: tens of thousands?
Cost of replacing 15,000 roller bearings: hundreds of thousands?
The look on the Senior VP's face when told he was the cause of the problem that he is forcing others to resolve by Monday morning: Priceless!
Just two questions - how did the conveyor contractor manage to get grounding springs installed on 14,994 rollers in one Saturday morning, or were just enough rollers grounded to accomplish the demo? And was that the permanent solution (seems that springs would eventually wear through), or did the bearings get changed back to steel?
Nice to see that the author eventually got into management and became a Director of Sales and Marketing. These positions SHOULD be filled by those who have come up through the technical ranks with competence, then problems like that described would not happen.
many years and jobs ago we were temperature testing a load cell application, the in final testing, the strain gages were practially blasted off the beam. Turns out a 200 volt spike on the liner of the temperature chamber when the power cycled. Careful shielding and insulation fixed the problem and it was a very late night.
A masterpiece of keen observation and deductive reasoning, leveraging a good background in physics. That your Sr-VEEP didn't give you a "career wedgie" for making him/her look foolish is a good example of political puckhandling, assuming it was the very same Sr-VEEP that complained about the noise.
On the technology side, although its gotten better over the years through awareness by chip vendors, I swear there were some CMOS chips out there that latched up if you gave them a stern look! I have an old CASIO Data Bank watch I still wear that occasionally latches its beeper ON when I slip off my coat on a dry, cold winter day. Luckily a single button press clears it, otherwise it would be a battery shark.