Drizzles, Documentation, and Discovering Root Causes | Diary Entry - 29th May, 2025
I didn’t know about the public holiday on account of Ascension Day until I reached the plant this morning - right on time, as per my usual routine. The gates were quiet, the corridors hushed. Only a handful of people showed up. A different energy - subdued, still, but sincere. We began the day with a prayer and our daily pledge. I always value these quiet starts, more reflective than usual, perhaps even more grounding.
The morning wore a curtain of clouds. A steady drizzle traced the outlines of the roofs and railings - not a downpour, but enough to keep the air heavy and the ground slippery.
I made my way to the Preheater#1 feeding bucket elevator area, navigating carefully. Accessibility is a challenge here. Spilled material mixed with water had formed a dangerous paste. Platforms were rusted, slick, and worn out. I noted similar conditions in other areas. It’s not just inconvenient - it's unsafe.
A Job Done Isn’t Always a Job Completed
One ongoing issue became clearer today: major and minor jobs are declared “completed” without proper documentation or structured reporting. There's no post-job summary, no visuals, no closure checklist. It leads to confusion, lack of accountability, and possible repetition of the same issues. I finally prepared an SOP titled:
“Execution and Documentation Protocol for Major Jobs Involving Replacement / Refitting.”
The idea is simple:
- Define the scope and timeline of the job.
- Assign clear responsibilities.
- Ensure photographic documentation at each stage.
- Record post-job inspection and sign-off.
- Maintain a shared repository (digital folder structure).
This isn’t just paperwork. It’s a cultural shift - from doing the job to owning the outcome.
DPM - The Gujarati Trio
Only three of us showed up for the Daily Production Meeting: myself, our HOD-Mechanical, and HOD-Process - coincidentally, all Gujaratis. It was a focused meeting, and I used the opportunity to share a few important habits for modern plant professionals:
- Photograph and video management: Transfer your files regularly. Don't let them rot in your mobile phones.
- Folder structuring: Use logical names and chronology. For example, "2025\_May\_BucketElevatorReplacement".
- Resize images before sharing: We often forward 8-12 MB images when 200 KB would suffice. Save space, save time.
These small digital disciplines build big professional habits over time.
DCT Visit - Rethinking the Routine
I’ve revised my routine recently. Instead of spending two hours at DCT during the lunch break, I now go after lunch. It allows me to:
- Visit the CCR and plant directly,
- Conduct short, purposeful meetings,
- Return early to WACEM and still be productive for at least one more hour.
This has improved my personal rhythm - but unexpectedly, not everyone is happy.
Unseen Losses - Driver Dynamics
I noticed my driver acting oddly for the past few days - passive-aggressive silence, delayed responses, a strange unease. After observing for a while, the dots connected. When I’d visit DCT during lunch, he’d get meal allowance. With my new schedule, that’s gone. From his perspective, it’s a small ‘loss’ - but enough to affect morale.
Lesson: In leadership, the big picture must not obscure the small discomforts of people around us. Even if the system is logical, the human side matters.
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Key Points of the Day - 29th May
- Reached the plant unaware of Ascension Day holiday - very low attendance.
- Visited dangerous areas near Preheater#1 bucket elevator; observed unsafe platforms.
- Realized lack of proper documentation after job completion; created a formal SOP for major job execution and reporting.
- DPM was attended by three HODs - all Gujaratis. Shared digital file management practices.
- Changed DCT visit timing post-lunch for productivity; created a more efficient schedule.
- Discovered my driver’s changed behavior was due to loss of meal allowance - an example of unintended consequences of operational changes.
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Reflection:
Today was a blend of observation and introspection - from unsafe platforms to unspoken grievances. Leadership is not just about decisions but understanding ripple effects - even the ones that fall quietly in the background, like today’s drizzle.
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