Z1 Alloy Incorrect

11DEC20: It was determined this morning that Andrew Dick had accidentally added double to required master alloy to a Z1 furnace melt on Thursday 10/Dec/2020 (101220A). It also happen again to the first Z1 melt today (111220A).

10/Dec/2020 Product:
1. Heat Button Samples were immediately analysed on CAA’s OES and determined that the heat was out of chemical specification.
a. AS2239-2003-Z1; Aluminium concentration 0.1 – 0.5%, Optical Emission Spectrometer (OES) determined 0.6% (0.1% high above maximum); Cadmium concentration 0.025 – 0.07%, OES determined 0.11% (0.04% high above maximum)
2. It was determined that a small amount of product had already been dispatched to Doen Pacific P/L against CAA Tax Invoice 51507; Doen PO 54266 and Doen Part Number DJ993; qty; 20pcs.
a. Product CDZ3-7S 2.2kg manufactured against Heat 101220A was also dispatched to 2 customers:
i. Marine Plus PO 13930; CAA Invoice 51497 (12pcs). ATS Group PO 346; CAA Invoice 51513 (25-30pcs).
ii. All 3 customers were notified by email 11/12/2020 providing explanation and requesting quarantining of said goods for inspection of hard stamped heat numbers (see attached). Marine Plus and Doen were also notified by phone call. ATS Group could not be reached by phone after 4 attempts throughout 11/12/2020. Upon confirmation by CAA customer of total numbers of quarantined goods, CAA will organise freight collection and return of non-conforming goods to CAA premises for reclamation. CAA may advise customer to destroy or dispose of product should the cost to return goods be deemed unjustifiable. Any non-conforming goods will be replaced at not charge to the customer
3. All other product produced on 10/Dec was quarantined and will be reclaimed slowly into future melts that will not have any effect on future melts conforming to chemical specification AS2239-2003-Z1 alloy.

10/Dec/2020 Product:
1. The non-conforming heat that was incorrectly double alloyed being 111220A was adjusted by Duncan Fergusson under supervision by Sam Pohlman. Virgin SHG Zinc was added to dilute the alloy concentrations back to our target position against AS2239-2003-Z1 alloy. The Heat was then authorised to commence manufacturing.
2. No product was manufactured from the initial non-conforming Heat 111220A.

1. Lang Semmler (GM) addressed staff members involved am 11/12/2020 and made all relevant persons aware of the issue. Sam Pohlman immediately quarantined all remaining non-conforming stock manufactured on the 10/12/2020. This product will be reclaimed slowly by remelt into future heats at a percentage that will not affect conformity.
2. A staff tool box meeting held to provide awareness of the incident and the following change to procedure presented for consideration, feedback and adoption.
a. Responsible Person starting and loading furnace from cold will be responsible for weighing and adding Master Alloy to furnace crucible with initial charge of ingot.
b. Should the Heat melting cycle be “finished” by anyone other than the Responsible Person who undertook Step 1 above, the Person finishing the melt cycle must confer with the Responsible Person would undertook Step 1 above to confirm:
i. Was the Master Alloy added.
ii. If “Yes” how much Master Alloy was added against projected number of primary ingots to be charged.
iii. If the Projected Ingot Qty does not align with the Actual Ingot Melt Qty, then the alloy composition must be checked by means of analysis on the CAA OES for determination of conformance prior to commencement of manufacturing.

LS followed up twice with Jason from ATS Group and Jordy from Marine Plus. DK advised that we received the returned faulty product from Doen.

Verification –
Reported by –BL
Closed by –BL
Date closed –January 18, 2021