Ways to Destroy Scrap Parts

[NewQM1975]

I work for a company that manufacturers small transformers and other electronics. During our recent AS9100 audit, one of the major findings was that even though we were trimming the leads and terminals off the scrap parts prior to disposal, we were not truly rendering them "useless", thus leading to the possibility that someone could "dumpster-dive" to retreive the scrap parts, and reverse-engineer them or splice leads to re-sell them back to the market. In response to this we have pitched several ideas, including cutting the parts with a bandsaw, hammering them, or drilling holes in them. These all may be labor intensive.

One interesting idea disposing of scrap parts came from an operator. He said that there are many days when they have excess epoxy that has to be cured and disposed of. His thought was that we could take some of the scrap parts and pour the epoxy over them in a bucket and cure the epoxy. Once cured we would just throw it in the trash. This would encase the parts in epoxy and no one would know that they were there. Would satisfy the requirement AS9100, 8.3? It would certainly take a lot less time than physically destroying them! Your expert comments are welcome.

 

[Michael_M]

Re: Destroying of scrap parts?

The requirement of AS9100 is:

Product dispositioned for scrap shall be conspicuously and permanently marked, or positively controlled, until physically rendered unusable.

Does pouring epoxy on them physically render them unusable?

I was told a story by a consultant (I don't know if it is true or not). An electronics manufacture was scrapping out circuit boards by spray painting them black. One of the employees was dumpster diving, getting the circuit boards, cleaning them with Acetone, and selling them back to the company. When it was discovered and investigated, it was determined that about 15%-25% of the 'scrapped' boards were getting through inspection.

Again, I don't know if this is true or not. It sounds kind of fishy to me but I am usually a bit more skeptical about these things then most.

 

[NewQM1975]

Re: Destroying of scrap parts?

Yes, it does render them physically unusable, because it's basically entirely encased in epoxy. But can someone dumpster dive and break apart the epoxy "mold" and retrieve the parts? I suppose theoretically yes...but it would be like breaking cement.

 

[Sidney Vianna]

Re: Destroying of scrap parts?

It would certainly take a lot less time than physically destroying them! Your expert comments are welcome.

Institute a "stress-relieve" program at the company where employees in need to unwind are welcomed to grab a sledge hammer and smash (scrap) parts...there....a quality improvement and an employee de-stressing program symbiotically created. HR and Quality holding hands....a beautiful thing.

 

[PaulJSmith]

Re: Destroying of scrap parts?

Can't you just drill a hole in it or crush it? Surely that would be more cost-effective than encasement.

 

[dsanabria]

Re: Destroying of scrap parts?

I work for a company that manufacturers small transformers and other electronics. During our recent AS9100 audit, one of the major findings was that even though we were trimming the leads and terminals off the scrap parts prior to disposal, we were not truly rendering them "useless", thus leading to the possibility that someone could "dumpster-dive" to retreive the scrap parts, and reverse-engineer them or splice leads to re-sell them back to the market. In response to this we have pitched several ideas, including cutting the parts with a bandsaw, hammering them, or drilling holes in them. These all may be labor intensive.

One interesting idea disposing of scrap parts came from an operator. He said that there are many days when they have excess epoxy that has to be cured and disposed of. His thought was that we could take some of the scrap parts and pour the epoxy over them in a bucket and cure the epoxy. Once cured we would just throw it in the trash. This would encase the parts in epoxy and no one would know that they were there. Would satisfy the requirement AS9100, 8.3? It would certainly take a lot less time than physically destroying them! Your expert comments are welcome.

That should work but pass it by the auditors or customer but you are meeting the intent of the standard - if they want the parts, they need to know what they look for and they probably destroy them in getting them out.

 

[NewQM1975]

Re: Destroying of scrap parts?

Actually we are trying to avoid any additional labor. Placing scrap parts in a bucket until it is full, and pouring waste epoxy over them would be much less expensive than having someone drill holes in each part. However, drilling of holes was actually touted as an idea and accepted by the auditors.

 

[normzone]

Re: Destroying of scrap parts?

The requirement of AS9100 is:

Does pouring epoxy on them physically render them unusable?

I was told a story by a consultant (I don't know if it is true or not). An electronics manufacture was scrapping out circuit boards by spray painting them black. One of the employees was dumpster diving, getting the circuit boards, cleaning them with Acetone, and selling them back to the company. When it was discovered and investigated, it was determined that about 15%-25% of the 'scrapped' boards were getting through inspection.

Again, I don't know if this is true or not. It sounds kind of fishy to me but I am usually a bit more skeptical about these things then most.

Not at all fishy. You can even throw out the selling them back to the company.

I was processing an NMR for a circuit board and noted that it already had an NMR number on it in my handwriting. I checked the number and it had been scrapped some time ago.

I found that employees were retrieving components I'd marked with Nonconforming Material Report numbers that they'd seen me put in the dumpster. They were slipping them back into the product flow.

They did this because "they knew those parts were difficult to get". Wrong thing, right reason.

So I made a show of hammering them in front of the crew before dumpsterizing them.

 

[Big Jim]

I can't picture how hitting the part with a hammer and destroying a significant feature on it would be any more time consuming that clipping the terminals. Besides, the hammer is more fun!

Or how about having a band saw near the scrap dumpster and either cut the part up or at least put a significant cut into a significant feature?

There has to be a fast and simple way to handle it.

 

[normzone]

I've also found that you can reward employees, almost raffling off the privilege, of lining up a bunch of parts and running over them with their car at lunch time. Thinking outside the bag the box came in, gentlemen...