These issues are usually outside the norm and it takes a number of factors to line up in order for it to happen.
As an engineer, I have been called to quite a few meetings to resolve the contamination. All the meetings actions can be categorised in three different categories: Detection, Fix and Managing Rework.
  • Detection is to implement early warning system to detect the issue early enough: this ┬ácan prevent the issue from turning into a full blown problem.
  • Fix is determining what went wrong and implementing the necessary fix.
  • And last is to recover the off-spec product and try to salvage the material by recycling it into the system.
Technical Article 06/08/2012: Contamination / Quality Issues goes into more detail into resolving these issues. More case studies will follow.