Document no. : QA-19-157 Rev.

Investigation Report
Customer : MAL MSHE

Mar 28th, 2019

Quality Assurance Team

Poongsan Ulsan Plant
1
D1. Use Team Approach

Teams Positions Name

Quality Assurance Team QA Section Manager S.U Park

Quality Assurance Section LF QA Assistant manager Y.M Ko

Rolling production 2 nd Team Technical Section manager H.J Chung

Rolling production 2 nd Team Slitting Section Manager J.P Kim

D2. Describe the Problem

Lot No Alloy Problem Quantity(kg) Size

87R62A0-A011, 021 C194-H Discoloration TBA 0.203X64.424

▶ We have received defect picture and sample from our customer and
there were some problem in side part of strip.
But this material were produced in August, 2018.
It's been about eight months since we produced it.

< Side discoloration picture >

2
D3. Containment Actions
1) Problem sharing
Action Details Name Date

1) Sharing defective information Mar 28th 2019

Team Team
Meeting members
2) Discussion for root cause Mar 28th 2019

2) Verify containment

Location Lot no. Size Quantity(kg) Packing Date Remarks

Keep
- - - - -
sample

WIP - - - - -
Finished
- - - - -
Good

3) Production history

Date Machine Remark

August 10th 2018 #1 WS

August 10th 2018 #1 CNC

August 13th 2018 #6 Auto packer

3
D4. Investigation
1) Sample Analysis _ SEM EXAX

Element Wt% At%

CK 01.02 05.15
PK 00.10 00.19
FeK 00.37 00.40
CuK 98.52 94.26
Matrix Correction ZAF

< Discoloration part > < EDAX Spectrum Result >

Element Wt% At%

CK 01.19 05.98
FeK 00.25 00.27
CuK 98.56 93.76
Matrix Correction ZAF

< OK part > < EDAX Spectrum Result >

▶ Like above result, there was no significant difference between defect part and OK part.

It can tell us that it is not related with copper material itself.

▶ It appears to be discolored due to the effect of air with very fine moisture or humidity.
4
2) Checking the weather

< Weather in Aug 2018, Ulsan>

▶ Red highlight part is packing day of defect product.

The temperature was high, but it wasn't raining. So, we don’t care weather effect in Ulsan. The climate in
Ulsan is not affect this material. Because storage period is very short and it is stored under
packing condition.

▶ It can tell us that discoloration is not occurred in slitting, packing process in Ulsan.
We assumed that discoloration accelerate by shipping atmosphere or local climate in Malaysia.

5
D5. Improvement Plan

1) Improvement Plan for packing Plan

Action

Schedule

Part Detail Machine 1Q 2Q 3Q 4Q

1 2 3 4 5 6 7 8 9 10 11 12

· Using drying room

· Increase desiccant quantity in vinyl Auto

Packer
Packing packing

Process
· Using VCI vinyl packing

· Using Al-foil vacuuming packing

Shipping · Increase desiccant quantity in

Container
Process container

6
2) Details corrective action
(1) Using drying room

< #1 Paper core drying room > < #2 Paper core drying room > < #3 Other packing materials drying room>
▶ First, setting drying room in slitting section.

< #1 Heater> < #2 Heater> < Humidity Checker>

▶ Second, using by heater, humidity of packing material can control under 10%.

- Almost of packing material humidity is about 6.0 to 8.0% after using drying room and heater.
- Before that, under rainy condition, humidity of packing material is over 15%.

7
(2) Enhance packing _ VCI anticorrosive vinyl packing

< Ready to packing > < Vacuuming > < Sealing > < Sealing with cable tie and tape(Detail)>

▶ Outside part of coil is packed by VCI anticorrosive vinyl and by using vacuum cleaner, remove the air inside of
packing.
* What is the VCI anticorrosive vinyl?

No corrosion

< MSDS of VCI anticorrosive vinyl > < Certification of VCI anticorrosive vinyl >
Test Condition
* VCI : Volatile Corrosion Inhibitor

- Under VCI anticorrosive vinyl packing condition anticorrosive material can evaporate and it can inhibit
corrosion of copper material.

8
(3) Using Al-foil vacuuming packing

▶ Like above process, we already propose Al-foil vacuum packing.

Unfortunately, we can not cover vinyl outside part of Al-foil.

9
D6. Request for customer

1) First of all, our copper raw material anti-corrosion effect is valid for 6months in packed condition.
Because copper is very susceptible to discoloration so, our material processed anti-corrosion treatment in washing process.
2) So, please keep dry condition or packing condition when our customer store our material.
3) It the material has been opened, use it as soon as possible, and when storing the remaining volume, please keep it sealed
and kept.

▶ Caution label.
- It is labeled outside part of pallet.

D7. Approval

Reported QA Section Manager QA Team Manager

Y.M Ko S.U Park M.H Jang

10
● Appendix

< After wipe off by white cloth>

▶ We have received PSM request and also wipe off by using white cloth, but side stain is not totally removed.
Some of them are weakened or removed, but they don’t disappear completely.
If this is an oil mark, it should flow down to the cutting surface and have same defect on the cutting surface.
But the same phenomenon doesn’t exist on the cutting surface.
▶ Like left picture, there was no oily mark.
So, we thought that it’s a discoloration, not an oil stain.
Discoloration has a wide variety of factors.
Especially, storage period, storage temperature, humidity
etc. So we respectfully request that our customer will use
material within the warranty period(6months after packing)
< Cutting plane>

11