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Date – April 23, 2021
Source of issue –Manufacture
Description –
CCE WA job (PO CWP-01234) for 98 x CDA-2200x245x238 drawing CD4068 rev1.
14 anodes had been cast when LS measured the dimensions of the anode bundles in prep for transport. LS discovered that the anodes had been cast in mould no. 15, rather than mould no. 14.
Immediate action –Cease casting. Remelt the 14 anodes to recover the 4 tonne. Get 14 new inserts fabricated.
Root cause –DB set up the incorrect mould. No staff checked the dimensions after the first casting.
Corrective action –
Anodes were engineered to very specific weight and dimensions, so the anodes could not be used. they have to be remelted.
LS called a Toolbox meeting. Conducted training to re-enforce the critical importance of checking the tooling against the Technical drawing and checking the dimensions of the first casting.
The delivery of these anodes is time critical so staff need to work additional hours to make up the time to meet the agreed manufacturing deadline.
We will implement a 2nd person check on the set up phase. For example, DB sets up and signs off as responsible for set up. DB then requests a 2nd person to undertake complete check of set up and they also sign as 2nd responsible person. It is mandatory that any custom anodes must be fully checked at first casting out of mould. This is not negotiable. LS and SP to police this very firmly.
Mandatory pre-production meeting within 24hrs prior to the job commencing so that everyone is on the same page with how the job has been costed and units per hour etc. This will be made easy by generation of a JOB SHEET in the Jobbing Spreadsheet
Verification –
Reported by –BL
Closed by –BL
Date closed –April 23, 2021