Sunmetal – Wet Ingot

05JUL16: RG inspected a zinc delivery and found some zinc bundles w evidence of water immersion during the cooling phase. One of the ingots had water under the surface (refer to RG email 05JUL16, which incl 4 photos)
It appears that 2 bundles were effected.

Note 1: Water on/in ingots can cause serious safety issues, as it can cause explosions.
Note 2: RG did not list the incident in the CAR system when the issue was first identified in July. This is why it was not discussed/reviewed at the Management Review meeting or ISO audit on the 26th of August 2016.

02SEP16: Sun Metals replied as follows:
Preliminary finding of the investigation into your non-conformance was as follows:

The mould chain and moulds that produced the relevant product was due for change out approximately 6 months ago. The change out kept getting deferred. This resulted in continued slackening of the chain, which resulted in more water immersion that would normally occur. As soon as your non-conformance was given to the production area the chain was immediately changed out.

Review of the process after the change out indicates that normal expectations for chain tautness and immersion have been achieved.

Once the investigation has been finalised I will let you know of any other learnings and corrective actions.

28SEP16: RG discovered cavity in Zn anode filled with water, depth of about 5mm (bundle Z0116092016A 1011). Refer to photo in RG email dated 27SEP16. Problem still occurring.

Verification –13SEP17: No more ingot has arrived wet since the incident was reported.
Reported by –BL
Closed by –BL
Date closed –September 13, 2017