INTERNATIONAL EQUIPMENT SURVEY LTD
IES
Shanghai Office:
Address: Rm 2108, North Building, Jinmao Garden, No2515
Pudong Avenue, Pudong, Shanghai, P.R. China
Tel: 021-68506618 Fax: 021-38715897
FINAL REPORT ON UES AT TLC
Serial No.: 100 x 40’H(Reefer) (SNHU800140 –800239) Date: Nov15, 2003
Up to today, 100 units were accepted after carefully inspection. General speaking, the overall quality was better under our efforts.
It’s first time for TLC to produce new Reefer for UES, and Mr.
Gong gave us suggestion and advice during production. ; Technical discussion and modification:
st1. Base coat system: 1 coat: zinc primer 30 microns for Corten part;
ndrd2 coat: polyamide epoxy primer 40 microns for MGSS; 3 coat:
Bitumen wax 200 microns for Corten and MGSS
2. 1 piece of EPDM and PVC film should be inserted between marking
plate and door panel.
3. Color sealant (RAL9010) shall be caulked around consolidated plate. 4. Reefer machinery is Thermo King CRR40
5. In ‘General description’, 4.1 item. Lower bottom side rail is made
with 4t, actual thickness is 4.5t.
6. Four (4) lashing bars to be installed between the outer two floor tees
on each side, actual quantity is six (6) lashing bars.
; List main problems on line, and actual remedies in harmony. 1. Rust remained on both edges of 4t panels after blasting/ we stopped
the line, and required foreman to put rusty plates aside for cleaning. 2. 20 pieces of 4t panels coated with zinc primer were pushed back for
re-blasting
3. Thin weld seams were noted around upper corner castings on front
frame/ factory didn’t design roof reinforcements for front and rear
header because they adopted 6mm steel for headers, so far we
requested foreman to keep full weld seams at the location 4. Thin and snaky auto-weld seams were noted between sub floors/ we
requested foreman to suspend work, and to debug machine
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immediately, and tested it soon after
5. Not good touch-up on base frame after welding, so much burnt zinc
primer and black dust remained on penetration between lower B.S.R
and sub-floor at corrugations, and factory just cleaned the location
with big round wire grinder/ we requested factory to use small wire
grinder to remove the defect sufficiently before stacking 6. Zinc primer holiday was noted on internal surface of lower B.S.R at
the beginning/ foreman and workers were confused how to treat coats
on MGSS and Corten steel, so we instruct them to paint the box
according to our requirement and working procedure
7. Zinc primer stage is dark in delve because factory doesn’t equip lamps,
thus workers couldn’t ensure the quality and location during zinc
primer application/ we requested foreman to equip the lamp
immediately
8. Foaming stages:
1) Factory equipped big plastic round roller to clean T-floor after fire
treatment, but the roller is very close to fire machine, especially we
checked out oil contamination on plastic swashed from chain of fire
machine/ it is serious problem, so we stopped line and requested
factory to install protective plate between chain and plastic roller 2) Ratty adhesion plastic films were noted on conveyer belt where
T-floor was stacked after foam bond application, and we checked out
remainders of plastic film sticking to foam bond/we requested factory
to replace it with new plastic adhesion film immediately 3) Uneven and inadequate foam bond was noted on T-Floor/ we
requested foreman to adjust spraying-gun
4) Worker cleaned holes of wood strips by driller aside mould while
another worker was spraying foam bond on side panel, thus the
ndremainders of wood and foam dropped on side panel, leading to 2
contamination/ we stopped their work, and educated them carefully
and strictly/ we requested them to drill the holes on the ground 5) 1-6mm gap was noted between front lower end B.S.R and foam strip/
we requested foreman to press the foam strip against B.S.R tightly
ndbefore foaming avoiding voids after 2 foaming
6) Delamination was noted between side lining and foam at one corner
for worker’s rough de-mould work/ we requested worker to dig out
ndfoam at the location thoroughly, and to repair it at 2 foaming stage
7) We checked out another serious problem at the beginning of side
panel foaming: workers forgot to clean off foam inside holes of wood
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strips, it ‘s serious bad habit leading to serious foam problems to a
certainty, such as voids and uneven foam density. So far we educated
all staffs and alarmed the action seriously, and requested factory to
re-organize workers and Q.C at the site, and teach them to reform the
working procedure.
8) Serious foam leakages from four corners of door frame at the
beginning/ we requested foreman to test free foam density, and to
cover the corner inside frame with one side adhesion paper 9) We rejected one door frame for serious damages and deformation on
door gasket of plymetal door panel.
10) One big void (200mm x 300mm) was noted in door frame/ we
required foreman to repair it carefully.
11) Several voids were checked out inside front side lining/ we required
Q.C to check the foam defects carefully, and to mark it with small
label for repair
12) Foam leakage from gap between door sill and PVC after corner
foaming/ we required worker to caulk the area sufficiently before
PVC installation
13) Water contamination was noted on top flashing side after bond
application/ we educated foreman and Q.C to put the flashing side
away, and to pay close attention to environment in workshop 14) The holes on rear and front header were welded fully/ we instructed
workers to avoid paint damages
; Suggestions:
1.Length of top close plate and cleanout panel fitting was not good, leading to gap/ technical staff should design it carefully. 2.Paint damages and contamination on units/ factory should continue to reform their facility and environments.
3.Slight wrinkles on HGSS around AEI corrugation/ the machine should be debugged carefully.
4.Factory started using new equipment such as fire treatment, electric treatment and auto spraying foam bond on roof panel/ At one time, factory should improve quality control method to meet new advanced facility.
At last, thanks TLC for rapid action and effective cooperation!!
Peter Li & Steven Lu of IES
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