| Problem |
Contaminant |
Source |
Outcome |
| microscopic black particles in fine powder pigment |
calcium carbonate reinforced carbon based rubber |
damaged and deteriorating final product filler hose |
hose replaced and contaminated product was recalled before delivery to customer |
| coloured defects on coated surface of metal wire consumer product |
high molecular weight coating gels |
cross contamination from previous product |
part recall was avoided because defect did not affect product integrity and was benign |
| metal debris passing magnets on newly constructed plant start up |
thin flat fragments of aluminium, one side printed, red and white |
Coca Cola cans from maintenance contractors discarded in plant |
plant start up not delayed. new contractor training introduced plus improved housekeeping procedures. |
| weld failure in construction material |
agglomerated powdery inorganic material |
single part of multi component additive pack due to incorrect blending |
independent analysis continued during process optimisation. Product replaced before completion |
| embedded particulate material causing bottle failure |
highly crystalline unmelts and degraded base material |
product build up in process plus incorrect process conditions |
material recalled, customer compensated. Returned material used as reclaim in different product. |
| replication marks on final product show face |
solvent residue causing localised chemical attack |
contact adhesive residual solvent and incompatible barrier properties |
customer successfully defended a disputed claim |
| flexible electronic product failure - metal track disruption |
exposed filler and associated agglomerates |
plastic substrate |
alternative higher quality grade substrate supplied. Customer retained collaborative research. |
| sudden unexplained outbreak of filters blocking on site boundaries |
environmental particulate debris plus high loading of distinctive fibres |
fibres from new plant on neighbouring industrial estate |
independent analysis and consultation helped both parties put measures in place to reduce emissions. |
| blocked narrow bore metal tube |
polymeric internal deposit |
equipment had polymer gaskets that were being chemically attacked |
gaskets replaced with alternative product and business retained. |
| stained product |
synthetic fibres. dye had leached due to temperature to cause visible stain |
cold weather fleece jackets |
garments changed and significant cost saving made due to reduction of waste product |
| smooth product with embedded defects and rough surface finish |
collection of general debris plus very unusual animal hair causing |
hair found to be from Monkeys getting into building rafters |
monkeys were dislodging debris settled high in the roof. Tighter “security” put in place. |
| poor optical appearance of transparent product |
significant increase in product residuals |
unexplained shift in plant operating conditions. |
plant conditions and chemistry subtly altered, downtime minimised and customer order met. |
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