The top sheet of a packet of steel sheets rusted due to moisture contact during transit while the remaining sheets were not affected. This occurred during the rainy season when the material took a circuitous transit route and the tarpaulin covering was not properly secured, exposing the top sheet to rain. As a result, the top sheet was rejected by the customer while the other sheets were usable, costing the company replacement costs. The planning team is involved for approving the indirect transit route without properly assessing protection measures during rain.

1. Is / Is Not Analysis Prashant Uttarkar
Problem Statement:
Rusty (Top sheet)
Is
Describes what does occur
Is Not
Describes what does not occur,
though it reasonably might
Distinctions
What stand out as odd
What object are affected?
What exactly Occur?
(Be a Specific as possible).
Final Product – surface finish look
dull, peel off, colour variation etc.
Water/ moisture get contact with
sheet of the Packet, due to
Continuous heavy raining
environment.
Top sheet Rejected by customer.
Rest sheet not become rusty due
to not come in contact with
moisture / water. Remaining
sheet not rejected and it is usable
to customer.
Only Top Sheet rusty. Water /
Moisture in contact with sheet.
Affected Aesthetically of final
product.
Where does the problem Occur?
1. Geographical location?
2. Physical location?
3. On an Object
Problem found in Customer end.
In transit, Material in wet
conduction
Supplier end, Customer
Warehouse. PDI report is ok
found.
Customer End. During Incoming
inspection
When does the problem occur?
1. When first?
2. When Since?
3. How long?
4. What pattern?
5. Before, during, after other
events.
During transit tarpaulin not properly
covered on Material.
In Rainy session, rusty problem
occur.
Customer use circuitous route for
transit.
Material dispatch to party
warehouse and then from
warehouse to party plant.
It is not continuous problem.
Other material directly
dispatched to Plant, does not
have any complaint about rusty.
Not is in other session i.e Winter,
Summer session.
Problem in Rainy session.
Customer use circuitous route.
During transit, tarpaulin not
properly covered on Material.
How: Extent of the problem?
1. How many problem?
2. How many object or situation
have problem?
3. How serious is they problem?
Top sheet Rejected.
Transits cost, replacement cost.
Extra cost to Company.
Other sheets not get rust.
RP oil on sheet, prevented by
getting rust
NVA cost added.
Replacement of rejected material.
Who is involved? (Not used to blame)
1. To whom?
2. By whom?
3. Near whom?
Dispatch and Planning team.
By checking Dispatch plan, Party use
circuitous route to transit.
Other than Planning person. Planning team.
Root Causes Tarpaulin not properly covered on
Material in a circuitous route.
CA Use RP oil, spread over top sheet
and all four side of edges of the
bundle.
PA Use HDPE + VCI paper for Packing
the bundle, when customer use
circuitous route.
Select the reputed Transporter.