He would often say，“In one hand we hold the wealth oflour nation, in the other the lives oflour comrades in battle！”
Nowadays still the reverberations of the“rubber gasket incident”are felt……
On the 17th of April 2009，the resident military representative was undertaking a routine inspection when he discovered three rubber gaskets'failure on the hydraulic operating system offaircraft. All the three faulty rubber gaskets had exposed burrs which should have been removed by knife.
The three faulty rubber gaskets were taken to Luo Yang's office. Luo Yang took them into his hands, and on studying them carefully he realized that these three rubber gaskets were three tiny disasters waiting to happen.Luo Yang was badly shaken, by them.
Luo Yang called the Chief of the Assembly Plant and asked him to remove all of the same type of rubber gaskets that had been already assembled into the aircraft, then to have him identify how many of the rubber gaskets had problems. He then called Plant Number 7 to immediately stop production.
In the afternoon, Luo Yang informed his office to immediately convene a meeting for the departmental leaders.
Arriving to the conference room, they saw Luo Yang, the sides of his mouth tight and his brow furrowed. The Party Committee Secretary, Chief Engineer and Deputy General Managers looked over the three failed rubber gaskets, and all were astonished.
Luo Yang said，“I have investigated the matter, in total 115 of these rubber gaskets fitted to the aircraft, two are found with this problem. The warehouse has 20，000 stored, and amongst those three to four in every hundred are faulty.”
People spoke one after another.
“Small rubber gaskets can cause a big problem. Once airborne, a faulty gasket can cause a malfunction.
In the history of aviation, at every turn there is the painful lesson of a single rivet, one small sheet or one pipe causing a problem, resulting in a deadly catastrophe.”
“We will usually fix our attention to the big problems that cause obvious harm, but as for the small problems on the periphery, they are easy to neglect.”
Luo Yang replied，“I want to ask everyone a question. What does it signify, that these three rubber gaskets were not discovered by us, but by a military representative?”
Without waiting for a response, Luo Yang answered，“This signifies a problem with the management. Everyone should see it like this, we produced the rubber gaskets, but why wasn't the fault picked up when they came from the plant?Why not when they entered the warehouse?Or why not when they were being fitted?If the management is rigorous, this problem would have been picked up through the various stages.However it was not.This only indicates that our management has a flaw！So I ask you all now, how do we manage this problem?”
Some said，“Take the remaining rubber gaskets and throw them into the furnace to cook！”
Others recommended“Deal with them just like pirated CD's, roll over them with a steamroller！”
It seemed as though Luo Yang had already decided, when he said，“Okay, this afternoon we will have a meeting in the production workshop of Plant Number 7，so that everyone can join in with our‘predicament'”.
At 15：00 that afternoon, Luo Yang arrived together with the leading group to Plant Number 7. The meeting space already had over 300 people, including Departmental representatives, various Party leaders, Heads of Production and Technology, the Assistant Plant Director for quality control and other employee representatives.
The meeting space had temporarily used a wooden box to set up a simple stage, on top of which sat two large iron drums, and next to them a large cardboard box half the height of a man. The Plant Office had informed everyone that there was to be an urgent meeting, and many people did not know the reason for convening.On seeing the set up of the stage, people grew even more puzzled.
Luo Yang walked to the stage, and scanned across the audience, saying in a serious tone，“Comrades, the meeting has been called this afternoon, for the following reason.”Luo Yang took hold of the box on the table, and grasped from within a few rubber gaskets in his hand.“These rubber gaskets were developed for[CLASSIFIED]aircraft. Yesterday during a routine inspection by a military representative, this faulty product was found, and in addition this faulty produce had already been fitted onto the aircraft.Maybe some will say‘Such a small rubber gasket is nothing, no need to make a mountain from a molehill！But who is brave enough to guarantee that these tiny faulty rubber gaskets wouldn't produce a problem once fitted to the aircraft?In the history of aviation, aren't there many instances ofilessons learnt from this?Originally I thought to just throw them away and be done with it, but on more thought I realized that this must be an experience that we all must undertake together.This afternoon, starting with myself every person here will come up here and cut ten rubber gaskets up each.'”
Luo Yang picked up a pair of scissors each and cut a gasket then threw it into the metal drum.
The corporation institutional leaders came next to the stage, taking the scissors and cutting them up, one after another.
Following on came, the Plant leaders and employee representatives, each looking somber, cutting in silence. Some of the female factory workers shed tears as they cut……
The large workshop fell into a space of quiet, so silent that one could only hear the ka, ka of the scissors cutting.
Luo Yang and other Corporation's leaders stood behind the stage and watched on the scene that nobody would forget.
Once everyone finished the cutting, Luo Yang again came to the stage, saying，“Just now, watching you cut up the rubber gaskets, I felt an unexplainable sense of pain. That such a small rubber gasket was flawed, actually, means that the person that produces the gasket was flawed, and the person that fitted the gasket was flawed also.If we are only to strengthen our quality awareness a little more, then the gaskets will not be flawed.I hope that when we leave today, we can think carefully about how to prevent this kind of thing from happening again……”
The punishment was severe：
Involved shift workers had their merit pay reduced for a month；
Relevant leaders had their merit pay deducted for the three months；
The criticism was publicized to the entire corporation.
The faulty rubber gaskets caused Luo Yang to take the entire corporation through a painful experience.
Regarding management, Luo Yang always insisted on putting people first, and adhered to a style of management with ethical conviction.
This conviction was not equivalent to mercy. Luo Yang treated his work with the utmost rigour, and was extremely tough with management.Corporation regulations stated that during team and cadre meetings there was no reason for lateness, and latecomers must stand throughout the meeting.During the meetings, if one's phone went off, they would have to stand until the meeting was over.Luo Yang said，“Our attitude is to guarantee good work, and if we cannot even guarantee our arrival time, we cannot respect the meeting regulations, how then could we guarantee our good work?”
Then in 2010 a high case industrial accident occurred at the sheet metal factory.
One of the workers went to the warehouse to receive some parts The parts were too many, and the sore-keeper was awfully busy. So he operated the stacker to take the parts on his own.Violating the operating specifications, he was seriouly injuried to his head by a falling iron part in volume of 600mm×200mm×30mm stored on a trap from the 7 metres high shelves.He was killed.
The sheet metal factory was one of the backbone factories of the whole Corporation, and the factory head had much authority, courage and talent. Luo Yang trusted him so much.Recently, when the Corporation undertook annual assessment tests, this factory would always be amongst the top assessed.
Nobody would have known that the sheet metal factory would have such a serious industrial accident.
The Head of the factory went to Luo Yang's office to offer his abject apology.
Luo Yang was furious, and with the pace of a lion he turned, confronting the Factory Head with the rebuke，“Let me ask you, are we a village production hut or a free market city factory?When a worker goes to the warehouse to collect parts, even if it is not with the store-keeper, and he himself operated the stacker. Shouldn't another store-keeper be permitted to assist?The regulations state very very clearly and are on all the walls, did you think they were posted up there just for decoration！Due to this violation, we have lost a worker, a person's life is over.Don't you understand the value of a person's life?If we loose a plane we can build another, but we can't bring back people from the dead！”
The Factory Head stood there, biting his lip with tears in his eyes.
Luo Yang calmed down, and said in earnest，“How many times have I said, we must value quality, value safety and proceed with extreme caution, yet we still have areas that are not up to the task. If we are only a little more responsible, and if we may implement our regulations 100%of the time, then accidents like this will not occur.”
Feeling tired, Luo Yang sat down, then continued，“Okay, I have said enough, you must wait for the outcome of your violation. However, first you must manage this incident correctly.The 80-year-old father of the deceased worker is lying in a hospital bed now, and if something bad happens to him now it will be on your hands！Also, the factory production is now at a critical junction point.If there is a problem with the factory you will be responsible.”
Arriving to work on the morning two days after the incident, Luo Yang received a letter from the plant manager, signed by over 200 workers from the sheet metal plant, reflecting the leader's research and production efforts, the work effort, the spirit of innovation and the particular care for each of the workers, and requesting from the Corporation that the leader may either not receive, or receive a lighter sanction for the accident.
Luo Yang held the letter in his hand, and said to himself，“Too late！”
A week later, Luo Yang received another letter which left him feeling emotional. The letter was from the father of the deceased worker, and he worte in it：
……
The Factory Head with Trade Union Director has waited on me by my hospital bedside for a week now, serving me tea and paying particular care towards me. Although I am in pain from the loss of my son, I am also moved by the meticulous care you have shown.The sheet metal parts plant has developed with fast momentum in the past few years, as there has been a good person at the helm.Reflected by the workers is the decency and vigorous work of the factory head, who is extremely particular about workers.
I am concerned to hear that the Corporation will employ sanctions on the plant. I do not wish that the factory head be punished due to my son's ill fate, as this will cause me to suffer, and only increase the pain I am feeling.
As the father of the deceased, in the name of an old worker of Shenyang Aircraft Corporation, and for the benefit of the whole factory, I implore the Corporation to refrain from punishing the factory head.
Such a measured, deep and meaningful father！The tide began to turn in Luo Yang's mind, as he thought of the Jin family, and of the common workers on the production line, toiling night and day. Those workers are the pillars of Shenyang Aircraft Corporation, holding the Corporation up.
It was very difficult to determine the punishment to serve the Factory Head during the General Managers Meeting, and Luo Yang did not expect so many people would implore leniency for the man. Many Assistant General Managers provided reasons that he should only receive a light punishment, and a heavy punishment would affect the positivity of the middle level cadres……
The meeting turned into a deadlock, and all eyes turned to Luo Yang.
With a solemn expression, he had been writing records in his notebook. Seeing that everybody now finished, he closed it, stood and said，“We have expressed many opinions today, and much has affirmed the merits oflour comrade, and I do agree with it.In recent years the metal sheet plant has developed well, and the affect on unifying the teams, executing projects has not gone unnoticed, nor has the Factory Head's work style, manner and ability gone unnoticed.Especially concerning the conduct post accident, although the Factory Head knew that he would be punished severely, he still worked diligently, suitably managing the accident whilst successfully completing the research production objective.”
However, I must ask us all, if we do not punish our comrade, or only provide a light sanction, what effect will that produce?
All were silent.
Luo Yang analyzed，“If we are lenient, some will ask，‘why have you put implemented so many rules and regulations?'If we are lenient, rules and regulations will lose their seriousness. If we are lenient, today some will break the regulations when collecting parts, and tomorrow others may break the regulations on some other matter, and it will inevitably become a vicious circle.Due to this, I believe that work is work, and what happened has happened, and a serious accident has occurred.The Factory Head, the person responsible, must take the responsibility to manage this problem.Now is not the time to appease, or to be soft.Have we not all seen the TV series Drawing Sword?The outstanding combat hero Li Yunlong breaks a military regulation, and instead of being dismissed he is re-instated as the Clothing Factory Head.Only later is the error realized and corrected, as he could always have been called back later.'”
The punishment was severe：
The Factory Head was relieved of his position, and reduced to his rank；
Those responsible for the accident were either dismissed or demoted.
Luo Yang wrote a detailed investigation on the matter to the China Aviation Industry Group, and requested that he receive a punishment himself.
One month later, Luo Yang was criticized in a report published by The China Aviation Industry Group, and 10，000 RMB was deducted from his annual bonus.
On a[classified]date in 2012，one of the Model 2 aircraft was undertaking experimental flight when suddenly the cockpit shield shattered.
Luo Yang organized the relevant experts to quickly investigate the cause of the accident.
After half a month, Quality Assurance Department Head Lin Bo received a call from Luo Yang.
Luo Yang asked Lin Bo，“Department Head Lin, last time when we looked through and analyzed the‘fault tree'，we found 23 problems that could result in assurance problems. I recall that‘sanded tempered glass'was one such problem.Although we have already checked that the problem did not come from this, I do not understand how we manage the sandpapering process.What sized sandpaper is used for the cockpit shield tempered glass from this model offaircraft?”
Lin Bo thought for a while, then responded，“Any size from 100 to 120 I think?”“What sizes do the design document regulations say?”“I don't think there is a specific regulation.”Luo Yang asked again，“What about the regulations from our manufacturer documents?”
“I don't think there is a regulation for this either.”
“Without a regulation, how does the Materials Department give the correct sandpaper size to the workers?”
“The old plans have all worked like this, and the Materials Department would send out sandpaper sizing by convention.”
Luo Yang grew anxious now, not letting the topic go，“Although the manufacturer documents don't have any regulations, how are the workers meant to know what size sandpaper to use?”
Lin Bo said，“Chief Luo, your question has stumped me. How about this, I will look into it, and then report straight to you！”
Lin Bo directed an investigation from two angles, the first was to read the design and manufacturer documents to discover that there were no regulations for the use of particular sized sandpaper, and the second angle was to investigate the purchase and usage of the sandpaper. Here the problem grew, as the warehouse only had a register of the sandpaper being purchased, and no register of the workers that would come to collect the sandpaper.After listening to Lin Bo's investigative report, his face darkened as he said，“Isn't this a quality problem?The design and manufacture documents have no requirements for the sizing of the sandpaper, but using a size 80 or a size 120 sandpaper on the tempered glass of the cockpit shielding will cause the thickness of the product to be different.This indicates that both the designers and the manufacturers are faulty, despite the fault being small.That the workers are not registering when they collect the sandpaper indicates more to me that we have chaotic management.”
Luo Yang called the Equipment Procurement Head and the Sheet Metal Factory Production Head together.
He said to them，“For such a large factory as ours, sandpaper is almost not worth a second glance. Exactly because of this we have a problem existing in our management.As it is extremely easy to collect sandpaper, we are invariable wasting what we have, and from the perspective of cost, it is increasing the costs of the operation.In addition, as we do not have specific requirements for using the sandpaper, we are promoting the arbitrary use of it, and we are saying that people use it as they please, like some kind of peasant economy, where farmers plant wheat when they wish this year, and corn as they like next year.What do you think?If this kind of arbitrariness were to become a habit, it will be absolutely incompatible with the management oflour modern enterprise.”
Luo Yang knew of the hidden dangers that existed within this small matter.
The Head of Equipment Procurement said，“Aside from this sand-paper, our management of other consumables is also not up to standard, for example gloves, torches, soap and other things are all stored and managed unclearly at the warehouse, and the procedure for collection is not at all strict. The‘sandpaper incident'has given us a wake up call, and we must establish strict rules and regulations for the procurement of consumables.”
Lin Bo said，“One aircraft is made up of hundreds of thousands of various parts, and there are many factors influencing the quality of the various parts. We usually pay close attention to factors affecting the quality, and perhaps we neglect the things that we are only indirectly responsible for.”
Luo Yang stated，“Mastering quality is achieved both by summing up our experiences, and by absorbing lessons. These lessons could even be considered a kind of wealth in themselves.The development of the aviation industry, and the improvement of technology are from some points of view achieved by the repetition of failures, and the accumulation ofilessons drawn from those fails.Do we not always say‘details determine success'?The‘sandpaper incident'is a result of detail, and can determine the success or failure of an entire aircraft！”
And so, lessons were learnt as a result of the sandpaper incident.
Rules were established corresponding to consumables management.
The Corporation also established the“Three Principles of Quality Responsibility”. These“Three Principles”were indicative of“Who Manages the Operation?”“Who Manages the Quality?”and“Who Takes the Responsibility?”Luo Yang's concept was that the quality of a product was not based on and a result of experience, but could be designed, and produced.It was necessary that every environment would have its own work quality, which could be used to guarantee the quality of the product.If the work procedure and quality both met the approved requirements, then the overall quality of the aircraft would likely be as expected.Previously, when a quality problem was identified, the issue would go to the Quality Department in the first case, whom would often also bear the majority of the accountability for any quality problems.After establishing the“Three Principles of Quality Responsibility”，the Quality Assurance Department would mostly act in a supervisory fashion when problems are encountered, including those that relate to whether management, responsibility and procedure was flowing smoothly, then providing comments and suggestions for improvement.In this way, all of the responsibility involved in product quality was comprehensively divided, and the product quality improved dramatically.As an example, although the J-15 was still in the research and development phase at that time, the rate at which it entered into the flight and then completion phases was not only first in class domestically, but also at an international level.The top class data delivered by the Corporation to achieve these superb rates were only made possible due to excellent product quality.
I have conducted interviews to relative depth regarding the modernization of managing complex science at Shenyang Aircraft Corporation, however still feel that I have not written enough, and find it difficult to give more vivid descriptions, just like friends of mine whom paint images of landscapes, nature and portraits with ease, yet struggle when confronted with the construction of the modernization.
Does literature and art reject modernization?I think not, rather writers and artists can't yet find the best way to describe modernization.
However, whilst reading Luo Yang's Enterprise Management essay, I found the“Stove Effect”analogy leaving a deep impression on me. He said，“Although young children have experienced little, they do not dare to touch a hot stove.Why is this?Because adults will tell them that they should not touch as stoves are hot.Of course, some children will burn their hands by touching a hot stove too, and learn not to do it again.As we master quality and discuss management, we should not spend our days speaking on‘empty principles'，instead finding ways to establish the“Stove Effect”，to allow all oflour employees to understand that neglecting quality management and overlooking rules and regulations will result in“hands being burnt”.With this simple principle, we will build and extend the implementation oflour rules and regulations.”
In this way, the modern management of complex science would become a straightforward principle；a habit of the employee. This is the art of a leader.
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