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Just working out in the yard and remembered this. Skip this post if you dont like long posts.

Competency crisis starts at the top. Back in the 90s I worked at a paper mill. if there was a problem with the machine they'd summon eveyrone to the control room and quickly triage the problem. My answer was 1)it was NOT my equipment, 2)it might be gauging related, 3)I'll fix my shit right away. I never lied or covered up and we had a great rapport. If I said it wasn't my equipment, they took me at my word and spend time in other places for hte problem.
Around 2012 upper management put a guy in charge of both paper machines who was not a paper maker. He managed problems on a big dry erase board and everyone got their name on the board. You had to fight your name off hte board by proving innocence. He would wait for everyone to prove their innocence before moving to another series of questions. the result was poor morale and it took 10x as long to get to the root of a problem.

Example. abrasion in the "wire" on the fourdrinnier table. The abrasion was about 6ft long on a 140ft wire. This machine runs at 3200fpm... 6ft is about 125ms. We had to prove that the actuators that move the slice lip hadn't jutted into the wire, cut it and rapidly retracted. Never mind that hte actuators moved in 77um increments and they were pneumatic stepper motors that did 4 steps a second. Never mind that the slice opening was 3inches.

This incompetency frustrates all your good people and they quit. We lost a machine superintendant in this time... he just packed up his shit and went to work at his dad's saw mill in Maine.

The next machine manager was from a union mill and liked it when he said jump and everyone jumped. He openly ran down the crew of one of hte machines because they wouldn't listen to him and pushed back when he wanted to run the machine a certain way. What he was too stoopid to realize was that crew knew the machine's limits better than him. Under his "leadership" a lot of 50 year old operators retired. They've been replaced with newer, dumber and more malleable guys who don't know any better than to jump when told. And the unplanned machine time suffers. Now we've got incompetent people at both ends!

And this my friends is how you take a paper machine that had 5 hours of unplanned downtime a year and make it have 72 or more hours a year. But boy when she runs, she's making 3400fpm!!!! Idiots all of them.

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It do be like dat sumtymez Mista Costanza