The factory team has investigated the case and reported as follows:
1. From production record of this lot, all process parameters are within standard.
2. For the problem of bad smell/ferment, if the product is under-processing, there should be more products were found fermented.
3. If the product is fermented, the bag should be blown off or have air in the bag and can be noticed. However, the customer informed only bad smell/fermented therefore it might be from the raw material such as part of the raw material are too ripen.
4. Therefore to prevent the problem of bad smell in the future, we have already implemented the following measures.
4.1 We revised the in-process inspection form to include the test for smell of the semi-product at every hour.
4.2 To revise the standard of ripeness of raw material for crushed. If the raw material is too ripen, it must not be used for crushed.
5. For the problem of less packing medium (high DW), since our spec is indicated at not lesser than 78% DW therefore we did not control for high DW.
6. To prevent the problem of high DW, we have already implemented the following measures.
6.1 To inform all concerned the problem of high DW and to control the variation of DW to max 85%.
6.2 QC inspector is to check the DW of the product at every 2 hrs and recheck the finished product after one day of production.