In the hardware industry, product rust prevention is an important subject in the industry. Rust not only affects the appearance and quality of the product, but also leads to the occurrence of safety problems. Therefore, rust prevention, is an important part of quality assurance in the hardware industry. In the past two months, we have experienced a quality risk from rusting our products

Generally, in order to avoid rust phenomenon, manufacture will finish surface treatment for the hardware products, and then delivery. This product is required by Japanese customers not to do surface treatment, but the product cannot rust. Through discussion, the customer will do degreasing before surface spraying. And during the product stamping processing, bending welding after cleaning will produce unnecessary costs, so after talking with our customers, we only do surface antirust oil to ensure that no rust.

According to the shipment plan, we finished the product processing several days in advance. The problem still happened during the shipment inspection. There was slight rust in the corner position of the product. We immediately correspond to confirm the possible causes of the product for all aspects. In the grasp of the defective rate and provide pictures for the bad product, Fujipunch timely contacted with customers. Fortunately, after seeing the picture, the customer thought it was slight, and did not affect the surface treatment, agreed to continue shipment. We checked all the goods in the warehouse, treated the rust spots, re-coated the antirust oil, adjusted the shipping date, and met the customer’s delivery date.

Although the bad phenomenon is acceptable to the customer, but in my heart it like a thorn. Because at that time is the Japanese epidemic serious time, many cities have sealed. The logistics cycle is very long, after the customer receives the product, the product rust situation will aggravate. If ignored, subsequent shipments will still be unsecured, contrary to the company’s emphasis on excellence. We can do better!

Decided to improve the problem, Fujipunch immediately action. Some people think that the general obvious bad are easier to find out the cause, in fact, it is not. At the rust product site 5 M confirmation, we also took a lot of detours. Aiming at the phenomenon of rust, we start from five aspects of “man-machine material method environment “. The first thing we think of is the SPCC of raw material and antirust oil. We confirm the oil model. It also takes a lot of time to compare the effect of the same product after oiling. Finally, through the statistical analysis of the bad phenomena, it is found that the rust position is basically concentrated in the corner and bending position of the product. So we immediately went to the scene to confirm the way of oiling. Due to the large size of the product and the limitation of the fuel injection tools, the workers do not completely cover the corner position of the product when spraying antirust oil, and the amount of oil in some areas is small, which leads to the occurrence of rust

If the reason is found, many people will say that since it is a problem, pay attention to the next production. In fact, to make good quality, any problem can not be hasty correspondence, this is our company’s consistent purpose. We first changed the original oil coating, from fuel injection to brush oil. Operation technique, oil quantity control, edge position brush oil method have made clear stipulation. Optimization of working methods, but also improve work efficiency, workers are also happy to accept new working methods.

Is the countermeasure method effective? Are you talking on paper? All also need actual verification. We use samples to brush oil, packaging and storage under normal production conditions. One day, two days, past; one week, two weeks… Two months later, through the transparent packaging bag, carefully confirmed the surface of the product, there is still no sign of rust. The problem has been solved, the next shipment can provide customers with more satisfactory products.

What can we do for customer satisfaction? It is easy to give up in the face of problems. It is hard to analyze the problem and find a reasonable solution. We choose the later one. To create revenue for customers, beyond customer expectations is our professional belief.