Lasers in a grill factory
Roughly 18 years ago at my previous job, a customer (large charcoal grill manufacturer) located in Georgia, USA calls to complain that their safety laser area sensor is broken and picking up things that aren't there. The sensor was used to make sure all humans and other impediments were clear of the area before a large welding jig moved at the start of the grill assembly line. I worked for the sensor manufacturer in New Jersey. Grill company is told that they will be responsible for $1000 per day plus expenses if I determine that the problem is on their end and not a failure of our product. The following week, a couple hours on an airplane from Newark to Atlanta, followed by a 2 hour drive in the rental car gets me to the front door. Just inside, 8 managers and maintenance staffers are staring at a laptop showing a realtime 2D map of what the sensor "sees". I watch the laptop and the jig for 3 minutes, then ask one of the "watchers" to place his finger on the laptop screen where the "false" trigger is showing up. 5 minutes later, the line is stopped for the scheduled morning coffee break and I can approach the equipment. I knock some welding slag off the end of the rig with my finger and ask the designated watcher if that matches what the "failure" they witnessed. They had recently changed to cheaper imported steel (creating more slag) and cut back on how often they cleaned the machine, never realizing that a sensitive laser sensor might receive a reflection from shiny falling metal shavings. I politely waited an hour before calling my boss and telling him to get the invoice ready. My return flight wasn't scheduled until the next afternoon, so I enjoyed my dinner and hotel room that night!
Biting the hand that feeds IT
