Howard, I just remembered we did the film on Classic Films Reloaded. I was just reading some of the pieces you wrote:
http://classicfilmsreloaded.com/pajama-game.html"Doris Day sang "Hey There" live during filming. She felt that it wouldn't look real to play the heart-breaking scene while lip-synching to a prerecording. Dramatically speaking, a live performance was more believable." - Howard Green
During the filming, dancer Carol Haney became very ill. Doris Day saw Haney brooding on the set and had a short conversation with her. Moments later, Day quietly walked to the middle of the soundstage and said, "Could I please have everyone's attention? - Unless somebody takes this lady to the hospital right this minute, I am going to walk off this picture. Either she goes to a hospital or I go. Thank you".
Director Stanley Donen made a financial deal with studio head Jack Warner to finish the film as far ahead of schedule as possible. This highly energized pace proved to be difficult for one and all. In the hospital, it was discovered that Haney was diabetic. So in a very real sense, Day saved Haney's life. "She totally became our hero for doing that", dancer Harvey Evans recalled. "Even (choreographer) Bob Fosse wasn't standing up for us, as we were being pushed and shoved and rushed through everything." - Howard Green
At first, after viewing his screen test, Doris Day wasn't sure about having John Raitt as her leading man. She suggested Howard Keel, Gordon MacRae or Dean Martin as possibilities to portray the role of Sid Sorokin. The producers, however, were determined to keep Raitt in the film and flew him out to California to make a screen test with Day. The screen test was a success and Doris was won over - but, sadly, "The Pajama Game" became Raitt's only leading film role. - Howard Green