So, I'm not sure if this fits this sub or not. If it doesn't please say so, I'll take this down, I mostly just wanted to vent.
Tldr: My boss (and previous bosses in her position) have always allowed us to break a certain rule in our area freely (because the reason the rule exists is a protocol we don't follow anymore). She saw me break the rule yesterday, got mad, yelled, and threatened/promised to write me up.
Long version (requires brief explanation of my job):
I work in a factory as a QA operator, I say 'operator' and not 'inspector' because most of the QA work is done by a machine, my job is mostly to operate said machine. The basic function goes like this: there are several 'stages' in the machine that each measure a different thing. Part goes to stage 1, gets measured, if its good it gets sent to stage 2, so on so forth. If a measurement is bad, the machine stops, a light flashes, alarm goes off, I now have to do my part. I take the part out, inspect the issue briefly, write a code on the part to identify what is wrong with it, and put it in what we call the 'kickout box'.
The box is actually two large, plastic boxes, each with two slots leading to an angled roller with a sensor halfway up. Each 'chute' goes to one stage on the machine, when that stage 'kicks out' a part, the part must be put into the corresponding chute. If the part doesn't go past the sensor in the right chute, the machine literally won't run. Also happens when the chute is full (each chute can only hold 3 parts), because the next part blocks the sensor. Obviously, yes, you just have to take the parts out. Issue is, it's locked, and only our group leader (GL) and higher have the key. So if I have 4 or more parts kickout of the same stage on my machine, I can't run unless my GL comes to unlock the box.
The reason this is like this is due to a protocol we haven't followed in 7 years, according to my boss, idk I've only been here 3 years. It used to be on the GL to PERSONALLY take each kickout part, inspect it, and see to it that it is either reworked, scrapped, or rerun. Obviously my GL has 10 billion other things to do and can't exactly handle this, especially on days like yesterday where my coworker had 150+ kickouts (not even exaggerating). Keep in mind, 150+ kickouts, when the capacity is 3, this is incredibly common. Naturally, we don't follow that protocol anymore. It is on us QA to handle these parts.
On my machine, however, there is a bypass method. Take the part out, flip a switch on the control panel to manual and back to auto, hit start… viola, machine runs and you can bypass the kickout box that literally does nothing. Not only have I done this countless times in front of every one of my bosses (GL, team leader [TL], and assistant manager [AM]), but I've literally been TOLD to use this bypass method since it just makes everyone's jobs easier. Yes, it is against the rules. But, like I said, the rule is for a protocol we don't follow anymore. This isn't just one of those “No, the rule has a purpose but you just think its stupid so you don't follow it” things, it literally serves no function. Parts go in kickout box, GL takes parts out, hands them to me. GL does nothing else here, no inspection, no watch to make sure I put them in the right place, nothing. Anything I could do by bypassing the kickout box, I can still do either way.
Yesterday; I had a part kickout, took it out, inspected it, used the bypass method, reran it through. My AM was apparently right behind me and I didn't know. I heard her yell “ARE YOU BYPASSING THE CHUTE?!?!” She continued on a whole rant then left after saying I could expect a write up. I'm confused, my coworker is confused, my GL is confused and sort of angry (this makes her job harder too). I don't get it… it literally has never been an issue for these past 3 years, why is it bad now?