Sharing of quality incident experiences~~~
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Have anyone encountered quality incidents in their work, related to safety, quality, testing, or something similar? Please feel free to share; it can also serve as a valuable resource for others~~~~~~~~Elites from all fields are welcome to participate actively~
At our factory, there was an incident in which the workshops altered the process conditions without following proper procedures in order to conduct experiments, which led to serious quality problems. At first, the quality control department didn’t pay much attention to the test results; it was only after realizing something was wrong that an investigation was initiated, but by then damage had already been done. The company imposed strict evaluations on both the workshop and the quality department; I think the quality department was a bit wronged~
During installation, a quality issue arose: the manufacturer of the flame arrester produced a defective unit, which caused backflow in the system and led to the internal components of the flame arrester being ejected. Fortunately, no one was hurt~~~~~
In the past, benzimidazole was used in the workshops to produce omeprazole, but sometimes, in order to increase production, hydrochloride was purchased instead. Both are packaged in cardboard drums, and aside from the name on the drum, their molecular formulas are pretty much the same. For a while, we used raw materials produced by Ah San; the containers were all labeled in English. Once, during the night shift, an operator who didn’t understand English mistakenly added imidazole instead of its hydrochloride form, resulting in the waste of a whole batch of imidazole raw materials.
During product filling, the regulations regarding the use of measuring equipment were violated; the total weight of the filled products and packaging materials exceeded the capacity of the scale, resulting in inaccurate weights. The excess was more than 10 kilograms per ton, causing an economic loss of 1,000 yuan per ton. In just one year, 200 tons of products were sold, resulting in losses of over 200,000!
This post was last edited by Gohan Transform at 11:38 on March 8, 2012. Our unit attaches the greatest importance to this! I haven’t encountered any problems with the rubber roller grinding machine yet, even though I’ve been at the factory now
A worker in our factory violated the safety procedures while using a grinder; he failed to turn off the power supply when replacing the grinding disc, and accidentally activated the power switch, which resulted in his right ring finger being cut by the grinder, with the tendons in the finger being severed. Was hospitalized for over a month.
Safety accident: In the reactor’s electrically heated heat transfer oil furnace, the circuit breaker tripped suddenly during production; the electrician performed no inspections before forcing the breaker to be turned back on. Instantly, sparks flew everywhere; the electric heating element was damaged by the current due to a short circuit, and the 350-degree heat transfer oil spilled out and ignited upon contact with air. The factory tried to put out the fire on its own but was unable to do so; it was only after the firefighters arrived that the fire was extinguished. Heart-stopping!
Safety accident: Hot work was carried out on the reactor pipelines, and the person in charge failed to conduct the required analysis of the combustible gas levels; it was outright illegal operation. As a result, the reactor exploded, causing the welder’s leg to suffer a comminuted fracture. Lesson: One must think carefully before engaging in special operations!
As for how you classify these quality incidents, we have classified this process change as a Type A change point that requires approval from the production management. If such a situation occurs without authorization, it will be determined based on the amount of direct loss to decide which level of quality incident it falls under; all those involved will be held jointly responsible and subject to penalties. Once the laboratory detects that the data does not meet the specified standards, it will immediately issue a quality anomaly report, which the production unit is then required to analyze in order to identify the cause and take corrective actions.
There’s no blame to assign here; quality management involves process control, and in daily operations, the trends of relevant parameters are not properly monitored