Priority · Critical · Active InvestigationLINE 2 · LIVE

IP67 Sealant Failure on High-Voltage Battery Enclosure during Line 2 Assembly.

Defect ID · HV-2419Assembly · Pack Module B · Station S-14Detected · EOL Leak TestOwner · QE.Rodriguez

Units Impacted

Containment

100%

RCA Progress

80%

Module 01

Dynamic 5-Why Analysis

Sequential interrogation from symptom to systemic cause.

1
Why 1
Water ingress detected during EOL (End-of-Line) leak test.
2
Why 2
Sealant bead thickness was 1.5mm (below the 3.0mm specification).
3
Why 3
The automated dispensing nozzle was experiencing flow resistance.
4
Why 4
Viscosity of the polyurethane sealant increased on the shop floor.
5
Why 5 · Root Cause
Root
No climate-controlled staging area for HV sealant materials prior to line deployment.

Module 02

Line 2 · Pack Module B · Station S-14

Bead Thickness

Spec ≥ 3.0 · Machine

1.44mm

Out of Spec

Sealant Viscosity

Spec 5–7k · Material

8390cP

Out of Spec

Ambient Temp

Spec 18–24 · Mother Nature

31.4°C

Out of Spec

Nozzle Pressure

Spec 5–7 · Machine

6.21bar

In Spec

Cycle Time

Spec ≤ 45 · Method

42.1s

In Spec

Streaming · 1.5s tick