9: Material/Product Issue
Definition/Typical Issues
Was there a variation or change in raw materials or products that led to the incident? Was there a difference between the anticipated raw materials or products and those actually used or produced in the process?
Examples of items coded under this node include:
- Raw materials
- Chemicals
- Intermediates
- Finished products
- Lubricating oils
- Sealing rings
- Glues/adhesives
- Spare parts
Note 1: Processing and manufacturing equipment is addressed under the Process/Manufacturing Equipment Issue (#7) node.
Examples
Example 1
- The formulation for a lubricant used by the facility was changed by the manufacturer. The facility was unaware of the change and, therefore, did not consider the effect of this change on the process equipment.
Example 2
- A supplier changed the part number for a specialty wrench. Although the wrench was still available, it appeared that the wrench was no longer stocked. As a result, there were delays in repair of a pump.
Typical Recommendations
- Provide appropriate specifications for raw materials.
- Verify that stock is current prior to its use.
- Establish a process to ensure a first-in/first-out (i.e., the first material placed in storage is the first material used [pulled out from storage]) usage pattern.
- Ensure that products meet specifications.