Dear Seetoh san and Ivan san,
As you may know, we TC Zero are facing with very difficult situation regarding the paint defect problems, delayed delivery of DRL, and schedule delayed for new parts installation training from TCST for the first lot of 55 units of MB5-F from Malaysia.
The DRL parts will be delivered on 8th Monday next week finally and its installation training will be started on Monday afternoon, which seems to be too late for our PDI operation starting.
Regarding the biggest problem of paint defects, our VDC Team found after washing and first inspection at NAM warehouse that all of 55 units of MB5 have the paint defect. These paint defects were confirmed by Mr.Philip Lu and Mr.Mike Luyun on Thursday this week at VDC at Latkrabang.
Please refer the pictures attached.
At the same time, I requested our Japanese professionals to investigate the real cause of these defects and the possible countermeasure as well.
Their opinion is that these defects are lots of iron oxide powders, something like yellow sand and a lot of dust, which might been put during the outside yard in Malaysia.
Our VDC Polish Team (Thai staff) has tried to polish one unit (Black), but not cleared off every defects.
Because they polished such iron oxide powders as it was and finally implanted the iron powders into the body surface.
By our Japanese professional comment, these iron oxide powders should be taken off by some special washing method first and then by the combination of light and heavy polishing method.
Yesterday afternoon, we transported one unit (White) to our Body & Paint shop @Bangna for Japanese Washing & polishing trial.
As the conclusion, we could confirm that Japanese professional can remove the paint defect by the special washing and polishing technique.
Please refer the pictures attached.
As I know these 55 units of MB5 should be delivered to branches and dealers by the next weekend.
At the same time, we are still struggling to clear off all 487 units of MY14 and MY15, as of 2nd February.
Regarding this issue, we have done 164 units already and almost finished 105 units. So, remaining 218 units are now at outside Body & Paint companies.
Adding to those situation, next shipment lot of 81 units of MB5-F has arrived to Thailand and we found again that 13 units of 25units have paint defects after washing and first inspection. Please refer the attached excel file.
Under these hostile situations for our goal, it seems very difficult to achieve the delivery dead line as you have planned and requested.
So, next question to all of you is what’s the first priority.
My proposal for these issues is;
① TC Zero to change the production plan of Special Washing & Polishing for MY14 & MY15 to the special activities for MB5 next week.
( I mean the rescue operation for 55 units of MB5-F will be the first priority.)
② The 55 units of MB5 to be washed and polished by our Japanese Professionals at Bangna. Not by Thai staff to avoid further damage on the body surface, especially iron powders.
③ After the washing and polishing of 55 units of MB-5 finished at Bangna, these cars to be sent to LKB PDI one by one for parts installation and final check.
④ Japanese Team to re-start for the activities for remaining 30 units of MY14 & MY15.
⑤ TC Zero to finalize the first quality check for second lot of 81 units of MB5 at NAM warehouse today and tomorrow.
⑥ According to the status of first QC of 81 units, the next countermeasure to be followed. It depends on the defect condition.
⑦ TC Zero to confirm the PGF (Paint Guard Film) operation to be started immediately from 15th Monday at TCMA Segambut Plant after CNY finish.
Could you please try to consider my proposal and the current severe situation for all of us and let me know your thoughts and views by return.
Thank you and Best regards.
T.Okamura