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Redgum Chassis PP-FP0172 Masking issue
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Description

AO received the first shipment of PP-FP0172 from Weiser on the on the 24th of May in accordance with the Rev IR instructions which I am told did not have the masking callouts which are derived from the Quiver Chassis design.  From what I've seen, none of the interior masking (3 areas) were done, nor was the two 8mm diameter masking locations on the back PEM nuts where the power connection goes.

  Given that these instructions may not have been communicated prior to their production run, and that I was told that these units were "Identical to Taz 6 but with different silkscreen" at the time I received them, this issue was not immediately noticed.  Some units were released for Alpha builds on May 24th and no feedback was given concerning this issue. 

We currently have 221 on hand according to Odoo(I can only confirm the 143 currently in QC however).  94 have been inspected and are at the Rockies location, I am unsure if any adjustments have been made for early builds.  If they require the masking callouts that the new drawings have(PP-FP0172, PP-FP0163), then these units will need to be recalled back to Aleph Mountain.

Given that this is a production quantity of units(221),  if it is necessary for them to be reworked I would advise using either Epocs, PMM, or Weiser to sand off the powder coat in the specified areas.

PMM has already done reworks like this before, so they would probably be the quickest option.

Action items

  1. Is rework necessary?
  1. Moving to get the reworks done.

Event Timeline

AOJAS created this task.Jun 26 2019, 7:59 AM
AOJAS triaged this task as High priority.
west added a comment.Jun 26 2019, 8:07 AM

IR did have all the masking callouts, the only extra masking callout from IR to A is masking around the usb cut out. We gave weiser PP-FP0172 to work from since they already had the chassis bent and welded. The internal masking is very important for EMI and CE. The 8mm masking circle is slightly less important since we passed EMI without it being masked. We need to have the internals powder coat free in the called out areas

AOJAS added a comment.EditedJun 26 2019, 9:17 AM

I'm thinking then that Weiser either didn't really look at these specs or that they didn't communicate them to their powder coat subcontractor in time to prevent the issue.

If that's the case then @jperry can try to have them fix this without cost to AO. The only additional cost they may want to(reasonably) charge us for is the additional 8mm diameter masking. I can make an NCMR for these and just follow the regular process for sending stuff back for rework based on this information.

Just in case it's needed for communicating with them, can someone provide the RevIR and RevA versions of the PP-FP0172 pdf here?

west added a comment.Jun 26 2019, 9:21 AM

I dont know the state of the chassis when they were sitting on them for a while, if they had already been coated or not. If they were then, in my mind, they would remove the powder coating on those areas.

AOJAS added a subscriber: tomc.EditedJun 26 2019, 9:44 AM

@tomc

Can you have James get a count on how many PP-FP0172 are in the boxes at Rockies so I can make the NCMR? We will need these brought back to Aleph Mountain Dock Receiving sometime in the next few days.

AOJAS updated the task description. (Show Details)Jun 26 2019, 9:58 AM
AOJAS added a comment.Jun 26 2019, 5:11 PM

NCMR created:
190626-20

Rework being requested on 210 units.

@jperry can you get an RMA number please to process these.

I sent an email to Weiser for these 3 NCMR's. I copied both Justin and Sheryl on that email.

kent added a subscriber: david.hall.Jul 1 2019, 7:56 AM

I was just talking with @kent about taking 15 of the chassis and grinding the ground locations ourselves. This will allow us to build the 15 WE printers (our production Beta run) this week. I believe that we can use a tool that we have in Cluster to do this process. Then we can move forward with building the 15. We would need to identify who is capable of doing the grinding and get that set up so that we can get these chassis to Cable/ harness, to get the 15 built, so that we can move forward with this build process @bowman , we will need to adjust the timing of the production schedule to reflect the issues with the masking on the chassis.

Next we will want to decide, if we are sending all the rest of the chassis back to Weiser for rework, what that will cost, what the time effect will be on our production schedule, so that we can decide how to proceed. @jperry please get with @bowman and @tomc so that we can all be on the same page for what we choose to do. If the first 15 chassis, work well, with us reworking them, then we could decide if we can handle all of the rework ourselves. @kent could work with all of us to see if that is possible or not.
@cmerot would like to get the Material Review board to get together to see what happened with this process and to help with the resolution.

kent added a subscriber: logan.Jul 1 2019, 8:53 AM

FYI, chassis rework OHAI that @logan made for the rework process: https://ohai.lulzbot.com/project/cb-sheetmetal-prep/taz-workhorse-edition/

kent added a comment.Jul 1 2019, 8:53 AM

I will schedule a material review board for these parts.

kent added a comment.Jul 1 2019, 1:52 PM

The MRB is disposed to rework these 210 chassis by using a rotary tool to remove the powdercoat around the USB port and the power supply mounting holes. We have a purchase request in for more sanding discs.

The first 18 of these are done and going to cables for being built today.

Make sure there is an MO out there as these weren't in the plan and yesterday we talked about 15 pcs.

I have my people in cables doing an MO from the manufacturing request for 18 that they are receiving today to do.

kent reassigned this task from kent to david.hall.Jul 3 2019, 11:54 AM
kent added a subscriber: kent.

@david.hall can you confirm with James that these chassis reworks are done and if so, close this ticket?

I believe that we have 144 done currently and we are using James for other work today. I will have him pick up on the last 3 boxes on Monday, then close the ticket.

kent added a comment.Aug 16 2019, 1:00 PM

This isn't a workmanship standard issue. In this case, the supplier just didn't do what the drawing called for.

kent closed this task as Invalid.Aug 16 2019, 1:02 PM