Color Legend:  RED= Open  Blue= Closed
Last Updated  ############
PAR# Date recd Problem Person reporting Ind resp. Mgmt resp. Report due date PAR implem. Date Report complete PAR implemented Status Comments Report 
1 3/3/2006 While putting slit orders there can be a human error where wide coil J. Rowe J. Rowe J.Rowe 3/7/2006 3/7/2006   closed  
  finish will not match with slit finish            
2 3/9/2006 Packing of Hi carton, need a standard for all shifts, so packing is  B. Frymoyer/ J. Laidig/ J. Laidig/ 8/15/2006 8/15/2006      
  always the same. Too much time lost on this. M. Sweitzer M. Collur/ M. Collur Frymoyer to write instructions for each     open  
B.Frymoyer item and give to John who will compile
3 3/9/2006 At recut, do lot of movement of long lengths due to due dates. This  Tim Hagans R. Jungberg M. Watkins 5/10/2006     open  
  damages the product.     Cost of racks to store and more warehouse space        
4 3/9/2006 3/8" or 1/2" sq long length shipouts too long, they bend when you pick Tim Hagans R. Bishop/BW M. Watkins 4/24/2006     open  
  them up with tow motor            
5 3/13/2006 For Haworth, Std tube/Closetmaid orders and all customers in general K. Veen M. Watkins/ M. Watkins 5/10/2006     open  
  Sales asks shipping to ship, but shipping cannot find the product.   S. Loos          
  This leads to orphaned material, FG and excess shippping expenses            
6 3/13/2006 Roof leak or a clogged gutter in area A-16 (MTS warehouse), causing B. Hofmann S. Capiottis M. Watkins 4/24/2006     open  
  damage to material in this area.             
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7 4/6/2006 9 mill buttwelder must be replaced - it works borderline at best and on  B. Miller B. Miller M. Watkins/ 5/6/2006 6/6/2006   closed  
  heavy gage does not work   S. Capiotis        
8 4/6/2006 #3 mill alignment problem-operator having difficulty aligning weld and Bruce Miller B. Walters/Strat B.Walters 7/1/2006 Sladky's report done, need plan to implement      
  maintaining good weld   & Sladky        
9 3/23/2006 Slit order 18994 does not state if all slits or any slits belong to 1800 Don Glass J. Rowe B. Hofmann 3/31/2006 4/7/2006 Y (4/12/06)   closed  
  Need to clarify whether to skid or put in bins            
10 3/25/2006 Lack of end machine dedicated to 4 mill causing undue downtime BS (8188) R. Bishop M. Watkins 5/24/2006 Now that we have retrofit reamer, we have dedicated wire brush   closed  
  fixing up machines from other mills       reamers on each mill. Need to ensure PM is performed on them      
11 3/25/2006 4 mill's 1.375" rolls are old and shot, giving ovality problems BS (8188) B. Walters R. Bishop 5/5/2006 1.375" rd will be scheduled on M2 mills with better tooling   closed  
12 3/25/2006 4 mill's 1.75"rd rolls are shot, ovality problems BS (8188) B. Walters R. Bishop 5/5/2006 New rolls expected 7/14 should solve this problem   closed  
13 3/25/2006 4mill's 610 oval rolls not ground properly - concavity problems - newset? BS (8188) B. Walters  R. Bishop 5/5/2006 Report recd from Bruce. Short footage of 100,000 ft per yr does not warrant purchase of new rolls.    closed  
Customer willing to take parts in current condition
14 3/25/2006 Bench exhaust units need to be checked for proper flow. At any time            
  at any mill especially #1 mill , smoke billows out into the dept. Fick (2297) B. Walters R. Bishop 5/5/2006 Work order completed 7/12/06   closed  
  Status:  WO 29730 cleaning during shut down, currently in working condition            
15 3/25/2006 Floor at 1 mill has deep holes. We run 20" tubing and balance it on one Joe Elacqua Leroy/Robin Bishop     Floor was cleaned and holes were patched over shut down.    closed  
    fork.Bander takes chance balancing it. If the truck will hit the hole, skid       A quote to resurface area      
  will fall.       around cutoff and front of drop table is being pursued by Strat of mtce.      
16 3/20/2006 Floor at #1 mill has deep holes. We run 20" tubing and balance it on 1 Zimmerman/Fick R. Bishop Zimmer/Fick 4/28/2006   4/28/2006   closed  
  fork.      Zimmerman/Fick to stop the spills as floor was fixed last year.        
17 3/20/2006 Cover plate on ream#1 not attached properly Zimmerman/Fick R. Bishop R. Bishop 4/28/2006   5/2/2006   closed  
Per Robin, mtce work order 29717 was submitted and completed as of 4/26/06
18 3/25/2006 Payoff wheel very hard to turn at 4 mill. Could cause injury BS R. Bishop R. Bishop 5/5/2006   5/2/2006   closed  
Submit a mtce WO Per Robin, completed by Mtce without work order on 4/17/06
19 3/30/2006 Bump marks in 1400 for item 1045676 Daniel Dougherty M. Watkins report by Mike sent to Mike Krout to be given to 1400 personnel Per Mike, this was addressed with the crew   closed  
20 3/30/2006 Bump marks in 1400 for item 1045676 Tom Wertz M. Watkins report by Mike sent to Mike Krout to be given to 1400 personnel Per Mike, this was addressed with the crew   closed  
21 3/30/2006 Bump marks in 1400 for item 1045676 Mike Julian M. Watkins report by Mike sent to Mike Krout to be given to 1400 personnel Per Mike, this was addressed with the crew   closed  
22 3/30/2006 Lack of supervision on 1st shift at 1400 entire 2nd shift  M. Watkins report by Mike sent to Mike Krout to be given to 1400 personnel Mike Watkins to send a report to 2nd shift employees   closed  
23 3/30/2006 Bump marks on 86488, mgmt continues to run line despite problems Jan Pilat (5978) M. Watkins report by Mike sent to Mike Krout to be given to 1400 personnel   closed  
24 3/30/2006 Steel certification: Steel should be certified before it is run on mills. If it is not S. Loos  B. Hofmann/ 5/1/2006 5/15/2006 Robin putting a code "NOC" 7/1/2006 7/1/2006 closed  
    certified, then it should be tagged a suspect so shipping knows that it cannot   S. Benner     for slits/coils without certs      
    be shipped. This could prevent shipping from accidentally shipping an order       Jim will not schedule this      
    that needs mill certs for it.       steel for customers needing certs      
25 3/30/2006 Benington item is racked under larger items, drip marks? Edinger (1744) M. Watkins/Eric 5/1/2006 5/15/2006     open  
Run under 2500 to avoid drip marks?
26 3/30/2006 Head speed needs to be repaired for Chevalier mill L. Mays (4990) Strat 6/30/2006 6/30/2006     open  
27 3/30/2006 Ways need to be trued up (cuts taper) - Clausing lathe L. Mays (4990) Strat 6/30/2006 6/30/2006   Put a capital for $3000, waiting for  open  
approval
28 3/30/2006 X-Y-Z ways need to be turned up (digital readout would improve accuracy) L. Mays (4990) Strat 6/30/2006 6/30/2006     open  
29 3/30/2006 All 0.014 steel for plating has spots/freckles in raw mostly with 0.865 OD Edinger (1744) W. Lamma/ Receiving inspection  6/30/2006 6/30/2006 10/3/2006 10/3/2006 open  
M. Collur given to Edinger
30 3/30/2006 Pressing 6B, 42,5A, 10A - Presses are too low to ground -raise them/ergonomics S.Traupman(8428) Ralph J   4/14/2006 4/28/2006   open  
31 3/30/2006 Floor uneven back at slitter going out into crane JR (6578) Strat Put in a cap. Request 4/29/2006 4/29/2006   open  
waiting for approval
32 3/30/2006 Floor uneven at 4 mill upender John R (6578) R.Bishop/ M.Watkins/Strat     open  
L. Knabb
33 3/30/2006 Had to wipe rust off and wip oil on tube and reskid (Inter-7073) JR (6578) R. Bishop/ M.Watkins/Strat 5/1/2006 5/31/2006   open  
  Columbia (10698) - tube rusting due to floor leaking (wood shop section4) Hauz(3015) L. Knabb          
34 3/30/2006 Poor management not enough people on 2nd shift to cover when  Bill Frymoyer B. Miller Bob Miller said jobs have been posted. We need to hire and train more people closed  
  someone is out 2539            
35 3/30/2006 Raw material/tubes from department 700 in recent weeks have lot of defects Edinger (1744) R. Bishop Mike assigned to Bishop 6/30/2006 6/30/2006   open  
36 3/30/2006 Rails are turned without the bolt on the inside. They catch the bottom  Edinger (1744) Eric/Bob J Mike assigned to Eric/Bob     open  
  of cranes causing wrecks, lost production and cause material to sit            
  in the tanks longer than its good for them until wreck is cleared.            
37 3/30/2006 Tubles smaller than 20" need to go into double skids. Moving shorter Edinger (1744) Bob Jungberg Mike assigned to Eric 6/30/2006 6/30/2006   open  
  lengths in singles are more likely fall off the forks and be damaged            
  in department while shipping            
38 3/30/2006 Lot of complaints on 1 mill due to scratches. Examine root cause as Fick (2297) Strat Mike assigned to Strat 6/30/2006 6/30/2006   open  
  contaminated coolant. If we screen coolant returning to recovery tank            
  through a large magnet will help scratches            
39 4/5/2006 Catwalk ramp between cutoff and sizing gets slippery from cooland/oil Alex Donkel (1140) Strat Mike Watkins 6/30/2006 6/30/2006   open  
  (suggestion: put a friction pad or rubber mat fastened to catwalk)   assigned to         
Strat
40 3/30/2006 Reamer and Swager rate sheet#3 new chart, parts are missing now Charlie E. Carlisle J. Laidig John Laidig gave new 1800 ream and swage rate sheets to Charlie and also added rated. closed  
(1062)  for over 85 cuts per min
41 4/17/2006 700 mtgs to be held in west conference room as there are interruptions Fick R. Bishop   6/30/2006 6/30/2006 Conference room will be used as closed  
  in grind room       required, will have mtgs in grind room  
42 4/17/2006 Quality statement sheets to be hung at time clocks-restrooms-locker Fick M. Collur   6/30/2006 6/30/2006 More quality policy statements closed  
  rooms       have been posted in lunchroom etc  
43 4/17/2006 Look at 1500-1.187" M2.5 RK5-96 rolls on rack not being used - rack Fick B. Walters   6/30/2006     open  
  congested, remove rolls that are not being used            
44 4/17/2006 Can data plate be installed on all square tubing torque head , this might Fick B. Walters   6/30/2006 6/30/2006   open  
  alleviate some of the guess work            
45 4/17/2006 Holes are punched with tabs bent over toward tap handle - coating M. Krout (4328) Ralph J Punch is changed 6/30/2006 6/30/2006 7/1/2006 7/1/2006 closed  
  Costing hooks do not seat properly - solution rotate punch to have tabs            
  bend over to bottom (toward leg end) - item 1046796            
46 4/21/2006 Reamer pin at 1 mil having lot of trouble on one mill from remaer or Fick Robin B   6/30/2006 6/30/2006   open  
  roller marks            
47 5/5/2006 Scheduling dept puts short 2" diameter lengths on 4 mill. The result is Mike Dunkle Bill H, Robin B   6/15/2006 6/15/2006 Lakewood item will be recut going  closed  
  cut off jaws are damaged beyond repair. (1554)       forward. Routings changed.    
48 5/9/2006 Can bushes be trimmed along parking are by employment office Fick Not valid PAR       closed  
49 5/9/2006 Catwalk ramp on 6 mill gets oil and coolant spray on them making it Alex Donkel Robin B/Strat   6/30/2006 6/30/2006   open  
  extremely slippery (1140) 2 work orders put in by Robin          
  soln: Put rubber mats on rampls or some kind of friction pads   3rd work order on 6/8/06 # 30379          
50 5/12/2006 Powder coating, Graco 85372, Fix source of problem in 1100, not in 1400,  Dan Dougherty Ralph J/Mike K/Jay C   6/15/2006 6/15/2006 Jay provided a report closed  
  makign 1400 employees do 1100 problem (grease on tube) (1547)       mfg/scheduling to utilize report recommendations to prevent this problem
51 5/19/2006 Benington packaging: High quality tubes getting no paper, no cardboard Edinger (1744) S. Gallagher   6/15/2006 6/15/2006 Steve G wrote  a note saying closed  
  on bottom, where the lift fork rubs against.       customer wants to try it due to their automated shop  
as operators do not have time to remove paper
52 5/19/2006 Positioning racking od drop pin work on our plating racks - lots of drips Edinger (1744) Eric B/Bob J   6/30/2006 6/30/2006   open  
  and slop marks            
53 7/28/2006 Tractor Trailer fumes during winter months when truck are warmed up. Fumes Fick M. Watkins M. Watkins 10/31/2006 10/31/2006   open  
  are ventilating inside building. Need vent hood in 1400            
78 8/12/2006 Tubing for item 1046139, Melnor was rusty, paint chips, light coating, bump  Chris Garber M. Krout M. Watkins 10/31/2006 10/31/2006   open  
  marks,ring gage did not fit, supervisor was informed of defects, but employee was             
  instructed to continue, loading and coating            
79 8/16/2006 Scouring of cutoff knifes. If knives were changed before scouring got too bad, David Breidgian R. Bishop/ R. Bishop/ 10/31/2006 10/31/2006 Routing change completed for all closed  
  they could be sharpened. The scoured ones can be used for recut orders   B. Walters M. Watkins   stack items - change cutoff knife    
  (we have many). Gary shultz did this on 5 mill tear drop every 3 hrs       every 10000 cuts    
80 8/14/2006 Somebody should check gage from beginning to end before we accept slit steel H. Stamm M. Collur/ M. Collur/ 10/2/2006 10/2/2006 Response given to operators with our closed  
  from outside with special reference to SLS steel M. Schammauer B. Lamma B. Lamma   Receiving inspection procedure. Do not inspect slit steel.
          Requested B. Lamma to track supplier metrics/rejects  
81 8/22/2006 Rust from drips and from sitting waiting for next process Chris Garber B. Hofmann/ M. Collur 9/30/2006 9/30/2006 PAR report submitted to C. Garber closed  
  Summo blanket order or stock order being run too soon. Order sit for too long   P. Sweigart     Back scheduled dates ok    
  and sometimes under pipes that drip. Causing rust. Sometimes rust is small       Customer service will maintain due   
  spots. Solution: runs orders at mills only when needed/ The less time between       dates, will not change dates once    
  processes the better.        product is produced off the mill    
82 8/22/2006 Tickets not correct. After process, no new ticket is made. Tickets still read Chris Garber M. Collur/ M. Collur 9/30/2006 9/30/2006   closed  
  119.00 inches rather than finished length. Scratched out order # with no date     B. Hess          
  or initials.            
83 9/12/2006 Cost Saving: Instead of ordering new top rolls, send example. 2. 1000 2.  .865 rolls David Breidigan R. Jeshoneck Ralph T. 9/30/2006 2/21/2007 New roll is cheaper than ID closed  
  to roll kraft and have I.D.s chromed.   M. Watkins      chroming      
84 9/20/2006 Excessive Rust. Increase coolant checks, install tube dryers at all mills to stop Fick R. Bishop R. Bishop 10/15/2006 10/15/2006   open  
  excessive water being pulled through sizing and tube oiler. Contact Roll Kraft or   M. Watkins          
  or different oiler.            
85 9/29/2006 5 mill or any mill not being able to see the problem with naked eye. My idea is to video Fick R. Bishop R. Bishop 10/31/2006 10/31/2006   open  
  record 5 mill at the end finisher. This would allow the tape to be slowed down and root             
  cause be identified immediately. This would take out all the guess work with the problem            
  of jam ups and down time. Note: If idea is accepted, please notify union officials            
102 9/27/2006 Safety: The yellow wooden ladder marked "1 700 looper" is missing the non-slip rubber  David Breidigan   9/27/2006   open  
  feet. It is now metal on concrete.  
103 9/29/2006 .750 Square rack needs new wheels. William D.     9/29/2006     open  
104 10/26/2006 Operators doing millwright work or electrical work not knowing what they are doing (not  Anonymous R. Bishop       open  
  qualified).  (no name -could be            
  Do not let operator do maintenance on machines. They do not know what to do or how to do it from 700)            
  They just try, but end up all messed up            
116 10/26/2006 Scrap (problem): Hire more QA people to monitor mills only. Do not ,et mill operator run order Anonymous R. Bishop       open  
  until QA person signs off (no name -refers to            
    mills hence 700)            
128 11/15/2006 Scouring of knifes: change knives more often to avoid scouring. As is being done on D. Breidigan R. Bishop M. Wattkins 1/15/2007 1/15/2007   open  
  #5 mill tear drop. It is working, grinding can sharpen and resharpen knives repeatedly   R. Bishop        
               
129 11/17/2006 Scouring of knifes: change knives more often to avoid scouring. As is being done on D. Breidigan R. Bishop M. Wattkins 1/15/2007 1/15/2007   open  
  #5 mill tear drop. It is working, grinding can sharpen and resharpen knives repeatedly   R. Bishop