These employees worked the new 12-hour shifts. It was reported that many more tires were scrapped while the replacement workers were building them than when the regular workers built them. Based on this information, it is likely that many tread separations can be traced to these inexperienced and overworked replacement employees.(because of a STRIKE)
It is clear that there were problems at the Decatur plant even before the replacement workers arrived. Former plant employees reported questionable manufacturing processes and quality control occurring well before the 1994 strike, including:
storing green tires on the floor and allowing debris to stick to the tires;
allowing hot and humid conditions inside the plant most of the time;
requiring tire builders to build about 100 tires per hour;
giving tire builders monetary bonuses for exceeding their quotas;
"repairing" blisters or knots in tires before placing them into the stream of commerce; and
failing to inspect, or properly inspect, all tires before placing them into the stream of commerce.
These poor manufacturing practices can lead to manufacturing defects and rubber-interface separation.
These former employees also reported that they used the same stock of green tires for all tire lines, and that tire builders and others in the plant did not change their manufacturing practices among different tire lines. Based on this information, all Firestone tire lines, including those built at plants other than the Decatur plant, may have been manufactured under the same questionable practices. Accordingly, Firestone tires other than those recalled by the company may contain manufacturing defects similar to those in the recalled tires.
Firestone did not identify any specific defects when it announced the recall. A representative said the company had not determined "what, if any, problem there may be with these tires."
This representative noted that the company's review of the relevant data suggested three things. First, the number of reported incidents with the 15-inch Radial ATX and ATX II was higher than with other sizes in this line of tires. Second, the Decatur plant was "overrepresented" in the accident claims and reports compared with the company's other plants. Third, the majority of the incidents occurred in the southernmost states, suggesting a direct correlation between heat and tire performance.
About one month into the recall, a Firestone executive said the company was looking into "variations in the manufacturing process at the Decatur plant" and "the unique design specification" of the recalled tires.
The company's statement regarding an overrepresentation of claims in connection with the Decatur plant and its investigation into manufacturing processes suggest a problem with the practices in this plant.