Dear all,

Date 19.05.15

This refers to the additional precautionary actions required during rainy season to prevent
rusting of parts. Generically following quality issues are observed in bought out parts during
rainy season due to lack of implementation of required preventive actions. --1) Press parts

2)
3)
4)
5)
6)
7)
8)
9)

Rusty & problem of excess oiling in case of Back plates resulting in

accumulation of oil in deep areas resulting problem during surface
treatment.
Cast iron w/cs, TMCs, CMCs, Rotors, Caliper, Carriers Red rust.
Bar Turned S/F parts eg Pistons Red rust.
Steel bars --- Red rust
Plated parts Black patches, white spotting or white rust, red rust, shade variation.
Rubber parts -- Wet condition of parts inside the Polythene bags.
Blackodised, Phospheted items White & red rust.
Powder coating, Painting & ED Coating poor adhesion & Paint peel off.
Reservoirs
Wet condition inside Polythene bags

All respective suppliers are requested to initiate following actions to prevent above quality
issues during rainy season --1) Corrugated material absorbs the moisture & the components (Specifically steel parts
like --Press parts,CI m/ced w/cs,TMCs,Rotors etc) if comes in direct contact with the
corrugated material, gets rusty even though oiled. Hence additional use of polythene
cover is must.
2) Rubber & plastic parts shall be thoroughly dried before packing.
3) The rust preventive oil shall be ensured for proper grade The FBML approved grade
is Anticore B1 -120 of Chorochem.
4) Oiling shall be done optimum to avoid excess or less amount of oil. Excess oiling of
parts creates problem for pre-cleaning while Surface treatment operation. In case of
less oiling parts gets rusty.
5) Strict process controls shall be ensured on surface treatment processes like
Plating, Phosphating, Blackodising, Painting, Powder coating & ED coating.
a) Wherever applicable baking operation shall be introduced for parts after surface
treatment process for effective drying / removal of water from parts surface
micro cavities.
b) Pre-cleaning process shall be monitored very closely for effective parts surface
preparation to achieve good plating quality.
c) Strict monitoring of plating thickness & passivation shall be done to achieve
required SST ( Salt spray test ) results.
d) Internal process audits frequency shall be increased to have close control on
overall surface treatment.
e) In this case also use of corrugated material for packaging results in deterioration
of plating, generation of black patches hence use of polythene cover is must.
6) Raw materials / components shall be prevented from rainfall by providing proper
storage area.
7) Periodic checking of stored raw material / components for its condition shall be done
to prevent its deterioration.

8) Ensure dispatch of material through vehicle having proper roofing & cover to prevent
water falling on material. Prevent rain water falling on material during loading &
unloading.
We hope that, the required actions will be initiated accordingly at your end to ensure
supply of components in rust free condition during rainy season.
Best Regards,

Subhash Wagh,
DGM CBI / PUQ IN
& Receipt Inspection.
Foundation Brakes Manufacturing Pvt. Limited.