Ruth Ibarra was the supervisor of quality inspection in the environmental
testing area. She began working in quality assurance (QA) in May of 1984.
QA was responsible for certifying that appropriate procedures were followed
in the testing of the chips. Because she was constantly in the environmental
testing area, Ibarra knew Margaret Goodearl and her supervisor, Donald LaRue
well. It was natural, then, for Ibarra and Goodearl to talk with each other
regularly about how testing was proceeding. Every hybrid chip had to come through QA for initial screening tests (e.g.,
is the paperwork correct? does it correspond to the chip to which it is
attached?) before being sealed. If any rework (for instance, resealing the
chips) was to be done on the hybrids, they had to pass through QA again
for further screening tests where the circuitry of the hybrid was compared
to the circuitry of an illustrated model. Finally, QA gave the paperwork
of each part the final inspection to verify that they had all been done
properly before the hybrids were sent to the customer. Ruth Ibarra's job in QA was to watch over the proceedings in the environmental
testing area. She supervised the QA people who did the initial checks and
who did the final checks on the paperwork before the chips left environmental
testing. In the process of walking around in among her workers, Ibarra's
job was to check on how the tests were being followed in environmental testing.
She did not supervise the "girls" in environmental testing, but she was
there as an inspector. The main tool she used in her inspections was a close
reading of the paperwork that followed each chip as it went through the
testing process. Each chip took about 10 days to get through the entire process of testing.
Paperwork called a "lot traveler" traveled through the process with each
chip. The lot traveler specified what kind of chip it was, and what tests
it should undergo. These lot travelers were the center piece of the whole
process. Everything that was to be done to the chips was specified in the
lot traveler, and once it was done, needed to be noted on the lot traveler.
When the part left the factory, the lot traveler stayed behind as the authoritative
record of what had happened to that particular chip. Thus, falsifying a
lot traveler was like lying about what tests were being done. The role of Ibarra and other supervisors was made more difficult by the
fact that some chips that were quite similar might have completely different
testing routines. For instance, about 2% of the chips being tested were
called "proof of design" chips that engineers were working on. These would
not be shipped to customers, but were for internal use as the engineers
tried out different designs. The engineers occasionally wanted these new
designs tested, and so would send the chips down to testing with their own
lot travelers specifying the tests they wanted. These would be tested differently,
and perhaps with more loose standards than the chips that were being sent
to customers. To make things more difficult still, every day some parts in the testing
room would be labeled "hot" by the management. This meant these needed to
be rushed through the process ahead of other chips so they did not spend
the usual 10 days getting tested. This allowed Hughes to rush the chips
out to customers who needed them quickly. Donald LaRue was in charge of
seeing that the hot chips got special treatment and went ahead of other
chips in the testing process. The chips were still supposed to be given
the tests required by the lot traveler, but if they were "in line" for a
test with chips that were not "hot" they would go to the front of the line,
and sometimes be hand carried from test to test so they could be shipped
quickly. This pressure between doing the tests correctly and getting parts out in
a hurry ended up causing tension between Quality Assurance and Environmental
Testing. Specifically, it caused tension between Ibarra, in charge of Quality
Assurance, and LaRue, in charge of seeing that "hot chips" got shipped as
soon as possible. Margaret Goodearl was caught in this tension and sided
with Ibarra, in favor of slowing the line down so there were no mistakes
in testing. This internal conflict of speed versus quality was the center
of the disputes that eventually arose. |
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