Trajan Scientific and Medical Pty Ltd

7 Argent Place Ringwood

Victoria 3134 Australia
Tel: +61 (0) 3 9837 4200
Fax: +61 (0) 3 9874 5672

Test report – TRXX

Furnace Oven – Defect And Damage Assessment
Distribution (Please refer to the Engineering Manager when allocating a distribution status)

Distribution Approved By Explanation

General Release This document is suitable for the public domain.

(Public domain)
 Very few test reports will fall into this category.

RESTRICTED Level 1 This document is prepared with the customer in mind.

(Customer release)
 Ensure that a customer NDA is in place before release.

This document is suitable for release to the global Trajan group of

RESTRICTED Level 2 companies. Trajan recipients worldwide must not forward this
(Trajan Worldwide)  document to any other parties without approval from the Engineering
Manager.
This document is suitable for release to technical personnel at the
RESTRICTED Level 3
(Trajan Ringwood)  Trajan Ringwood. It must not be distributed to any other party without
approval from the Engineering Manager.
RESTRICTED Level 4 This document is suitable for release to R&D Group, Senior
(Product Development and  Management and Directors only. It must not be distributed to any other
Operations) party without approval from the Director of Product Development.

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(Board of Directors)
 distributed to any other party without approval from Trajan CEO.

Distribution approval column to be signed, at the appropriate level, by the author’s manager.
Revision responsibility resides with the author or the manager’s nominated delegate.

Initiator: Responsible Engineer:

Name: Kartikkeyyan Loganathan Name: Kartikkeyyan Loganathan

Signature: Signature:
Date: 13-May-2022 Date: 13-May-2022

Reviewed By: Reviewed By:

Name: Nareshkumaar Poorpatham Name: Jethesh Prabhakaran

Signature: Signature:
Date: 17-May-2022 Date: 17-May-2022
 Contents
Test report – TRXX ................................................................................................................................. 1
Executive Summary ................................................................................................................................ 3
Background ............................................................................................................................................. 3
1.0 On Receipt at Trajan Malaysia .......................................................................................................... 4
1.1 Unloading and un-crating .............................................................................................................. 4
1.2 Shock indicators and Tilt indicators ............................................................................................... 5
1.3 Positioning the Furnace ................................................................................................................. 7
2.0 Root Cause Analysis ....................................................................................................................... 10
2.1 Failure Mode Scenario ................................................................................................................ 11
3.0 Damages and Defects in the Furnace ............................................................................................ 12
Risk Assessment ................................................................................................................................... 14
Conclusion............................................................................................................................................. 14
Appendix ............................................................................................................................................... 15
Report No: TR1219 Rev: 00 Prepared by: Title: Page 3 of 15
Date: 10-May 2022 Wesslee Licup Furnace Oven – Defect And Damage Assesment
Project Code: B119

Executive Summary
The Furnace oven which was purchased for the Printing capability transfer to MYS was received in
damaged condition upon arriving at Trajan MYS. The core hypothesis or most likely event that caused
the damage inside the oven is solely due the untighten or loose moving parts. This scenario has led to
impact on project transfer timelines and additional costs to be included in the project which was
unforeseen.

Background
Trajan Scientific and Medical (Trajan) purchased a furnace oven (Image 1) from RGL Enterprises
(RGL) based in Phoenix, Arizona/USA.

 The machine was assessed by Trajan at RGL’s site by a Trajan Engineer, Mr Javier Rangel, prior
to shipping
 It was assessed to be in very good/excellent working order but no reports(FAT) were made
available upon preparing the oven for shipment or the securing the moving parts.
 The machine was shipped from Arizona to a Californian port by land, USA to Malaysia (Penang)
port by sea and Penang port to Trajan Malaysia site by land.
 Packing at origin was undertaken by RGL, Expeditors International were engaged to ship the
packed container (door to door) and unloading and unpacking at site by Trajan.
 During the initial pre-commissioning steps at Trajan’s Malaysian site, several damage and defects
were found inside the oven and no visual damage or defects found externally.

Form # 5500724
Report No: TR1219 Rev: 00 Prepared by: Title: Page 4 of 15
Date: 10-May 2022 Wesslee Licup Furnace Oven – Defect And Damage Assesment
Project Code: B119

1.0 On Receipt at Trajan Malaysia

1.1 Unloading and un-crating

The furnace arrived and was in situ at

1 Trajan’s Malaysia site on the 19 Apr
2022.

The container and contents including

packaging arrived in good condition,
2 the container being returned to the
shipping yard without any claim for
damages.

The container was inspected after

3 unloading the crate. No debris or extra
boxes found inside the container.

Form # 5500724
Report No: TR1219 Rev: 00 Prepared by: Title: Page 5 of 15
Date: 10-May 2022 Wesslee Licup Furnace Oven – Defect And Damage Assesment
Project Code: B119

1.2 Shock indicators and Tilt indicators

Upon unloading the crate, the shock indicators were visually inspected. All four indicators were green
which proves the crate did not receive any external shocks.

1 Shock Indicator 1

2 Tilt Indicator 1

Form # 5500724
Report No: TR1219 Rev: 00 Prepared by: Title: Page 6 of 15
Date: 10-May 2022 Wesslee Licup Furnace Oven – Defect And Damage Assesment
Project Code: B119

3 Shock Indicator 2

4 Tilt Indicator 2

Form # 5500724
Report No: TR1219 Rev: 00 Prepared by: Title: Page 7 of 15
Date: 10-May 2022 Wesslee Licup Furnace Oven – Defect And Damage Assesment
Project Code: B119

1.3 Positioning the Furnace

After un-crating, the furnace

was found wrapped with a foil
1
sheet and plastic wrap, secured
with metal straps.

The metal straps were

2 removed, and the foil wrap was
cut open.

There were broken insulation

3
found below the furnace.

Form # 5500724
Report No: TR1219 Rev: 00 Prepared by: Title: Page 8 of 15
Date: 10-May 2022 Wesslee Licup Furnace Oven – Defect And Damage Assesment
Project Code: B119

 The damaged insulation of

the heating zone.

 These images were taken

before the furnace was
lifted with forklift.
4
 This proves that the
damage occurred before
the furnace was loaded
into the forklift at the MYS
facility.

The forklift placing the furnace

5
on the lift

The crane is about to lift the

6
furnace.

Form # 5500724
Report No: TR1219 Rev: 00 Prepared by: Title: Page 9 of 15
Date: 10-May 2022 Wesslee Licup Furnace Oven – Defect And Damage Assesment
Project Code: B119

7 The furnace is being moved to

second floor

 The furnace was placed in

its appropriate position as
planned.
8
 No sudden shocks or
impacts receive by the
furnace through the
process.

The entire unloading, un-

crating, lifting, and position the
9
furnace was recorded and well
documented.

Form # 5500724
Report No: TR1219 Rev: 00 Prepared by: Title: Page 10 of
Date: 10-May 2022 Wesslee Licup Furnace Oven – Defect And Damage Assesment 15
Project Code: B119

2.0 Root Cause Analysis

In the determination of root cause, the machine was damaged due to failure of not securing moving
parts inside the furnace.

 The damages and defects started to occur most likely during transit, were it was packed and
shipped.
 The moment the furnace started to move in its mode of transport, all the shocks, impacts,
transport vehicle absorded was transfered to the moving parts inside the furnace.
 This movement cause the damages and defects that was found inside the furnace.

We can analyse the way which all the deflections, cracks, and damage propagates through the
internal parts of the furnace to determine the points which the impacts originated from as below;

Feed-In
Feed-Out Chiller Insulation

Furnace Side View

Furnace Top View

The damage is maximum at the location where the chiller is connected to the insulation module and
spread across the furnace as shown in the above image.

Form # 5500724
Report No: TR1219 Rev: 00 Prepared by: Title: Page 11 of
Date: 10-May 2022 Wesslee Licup Furnace Oven – Defect And Damage Assesment 15
Project Code: B119

2.1 Failure Mode Scenario

The below images shows, the motion of the screws that allowed to move when the nut is not tighten or
loose.

An untighten 13mm diameter screw can move easily inside a 34.5mm slot with 1 mm gap around it as
shown below,

As shown in the below sequence images, the loose screws will cause a back and forth swaying motion
to the chilling unit, making it to act as a “battering ram” effect against the insulation body. The
furnace travelled for months at sea. This explains the severe damage that the insulation of the heating
zones took.

Form # 5500724
Report No: TR1219 Rev: 00 Prepared by: Title: Page 12 of
Date: 10-May 2022 Wesslee Licup Furnace Oven – Defect And Damage Assesment 15
Project Code: B119

3.0 Damages and Defects in the Furnace

The furnace was inspected for damage and defects with details as below,

 There is no deflections, defects, and damages found at the exterior body or the frame of the
furnace.

 All the damage and defects were found inside the furnace only.

The table below show all the damages and defects found inside the oven.

No. Damage and Defects Remarks

The cracks on the insulation

originated from the left (the point
where the chiller located) to
1 right, and it stopped three
insulation block before the feed-
In of the furnace.

The point where the insulation

2 and the chiller is located is
where the damage was heavy.

Form # 5500724
Report No: TR1219 Rev: 00 Prepared by: Title: Page 13 of
Date: 10-May 2022 Wesslee Licup Furnace Oven – Defect And Damage Assesment 15
Project Code: B119

The most of the broken quartz

glass where found near the
3 damaged insulation beside the
chiller

 The most bended metal

plates found between the
damage insultion beside the
chiller.
4
 The metal plates in between
the insulation at the feed-in
was perfectly fine.

All the Broken and Cracked

5 Heating Blocks were near the
chiller.

Form # 5500724
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Date: 10-May 2022 Wesslee Licup Furnace Oven – Defect And Damage Assesment 15
Project Code: B119

6 Broken Weld

7 Untighten and Loose screws

Risk Assessment
Potential Risks Effect Risk Probability Risk Severity Risk index
Unsecured Moving Parts (Furnace Damage to internal
1 5 4 20
Internal) components

Conclusion
Based on the information available and the associated conditions noted, all the damage and
defects are solely due the unsecured moving parts inside the furnace.

Form # 5500724
Report No: TR1219 Rev: 00 Prepared by: Title: Page 15 of
Date: 10-May 2022 Wesslee Licup Furnace Oven – Defect And Damage Assesment 15
Project Code: B119

Appendix
Risk assessment criteria: Probability x Severity = Risk index

Probability Rating Severity Rating

Disastrous impact. Death or serious, irreversible injury or harm.
5 Nearly certain to occur. 5 Will cause significant cost increases, or loss in operational
performance.
Significant impact on accuracy, repeatability, reliability or
4 Highly probable to occur. 4 performance of product. Serious but reversible injury or harm
Noticeable cost increases, or loss in operational performance.
Moderate impact on accuracy, repeatability, reliability or
3 Occasional occurrence likely. 3 performance of product. Minor injury or harm.
Moderate cost increases or loss in operational performance.
No perceivable impact on accuracy, repeatability, reliability or
2 Remotely possible to occur. 2 performance. Nil or negligible injury or harm.
No noticeable cost increases or loss in operational performance.
No impact on accuracy, repeatability, reliability or performance.
1 Extremely unlikely to occur 1 No harm.
No noticeable cost increases or loss in operational performance

Risk Index Required Action

15 - 25 Very high risk, substantial mitigating action required

10 - 12 Significant risk, mitigating action is required

6-9 Moderate risk, mitigating action may be required

1-5 Acceptable risk, NO action required

Form # 5500724