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Procedure when piece of metal found in the product by metal detector?


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ts33

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Posted 18 July 2014 - 11:30 AM

If a piece of metal found in the product by metal detector, what is the standard procedure to follow?



Mr. Incognito

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Posted 18 July 2014 - 11:33 AM

What product do you make?


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Setanta

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Posted 18 July 2014 - 11:56 AM

What we do is to place everything from that line or machine on a Quality Hold back to the last successful metal detector failure. For us, that's one hour of production, which can still be quite a bit. We then set up our a line if available, or a spare metal detector to re-run all the the product made during that time under the same level of metal check.

If there are no failures, no metal detected, we release the product.

Setanta


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cazyncymru

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Posted 18 July 2014 - 12:07 PM

What we do is to place everything from that line or machine on a Quality Hold back to the last successful metal detector failure. For us, that's one hour of production, which can still be quite a bit. We then set up our a line if available, or a spare metal detector to re-run all the the product made during that time under the same level of metal check.

If there are no failures, no metal detected, we release the product.

Setanta

 That's exactly what we do.

 

If we do get a rejection, we do a wash out to try and identify what it is and then do a RCA

 

Caz x



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Posted 18 July 2014 - 12:09 PM

Setanta that's the procedure if your metal detector fails a test.  He asked if the metal detector finds metal.

 

I asked what you make because the procedure can be different. 

 

In 2 of the factories I've worked in we packed a dry product so what we did was we pulled the failed product off of the line and then inspected the contents to find the piece of metal.  My current job is bagged flour so we have a stand alone metal detector we can pass the bagged flour through to find the piece of metal (50 lb bags).  The other one was pasta so they just opened the box and the operators spread the pasta out on a plate and looked for the metal.

 

If no metal was found then they inspected the packaging to see if the metal was there.

 

Then they fill out a form that has the results of the inspection.


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Posted 18 July 2014 - 12:11 PM

Also I forgot: take the piece of metal to your maintenance crew to try to ascertain if a piece of equipment is breaking down so they can keep an eye on the system.  And thank your metal detector for doing a fine job.

 

It's always important to remember that it's good to have your metal detector find metal... that's what it is supposed to do.  Some people freak out when metal is found in the product.  Could it be a problem.  Sure.  But you found it.  Now determine if it is a piece of equipment breaking down that needs attention or if it came in through operator error or an ingredient... make sure you have a record of it... maybe talk about it at a food safety team meeting "Hey we had a metal detection, the operators found the piece of metal, and I gave it to Maintenance to determine if it's from our equipment." 


Edited by Mr. Incognito, 18 July 2014 - 12:18 PM.

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Posted 18 July 2014 - 12:17 PM

Setanta that's the procedure if your metal detector fails a test.  He asked if the metal detector finds metal.

 

I asked what you make because the procedure can be different. 

 

In 2 of the factories I've worked in we packed a dry product so what we did was we pulled the failed product off of the line and then inspected the contents to find the piece of metal.  My current job is bagged flour so we have a stand alone metal detector we can pass the bagged flour through to find the piece of metal (50 lb bags).  The other one was pasta so they just opened the box and the operators spread the pasta out on a plate and looked for the metal.

 

If no metal was found then they inspected the packaging to see if the metal was there.

 

Then they fill out a form that has the results of the inspection.

 

That's very similar to what we do. We produce rolls/bread and if product is rejected, maintenance is immediately notified to begin going through the product to find the metal. Based on where it is found within the product (in it, on the bottom, etc.) maintenance will then inspect all the equipment to determine a source and make any repairs. The metal and lot information of the bag is taped on a form that is then completed by maintenance with the results of the inspection and actions and turned into me. All metal findings are tracked in a spreadsheet for easy trending.



Setanta

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Posted 18 July 2014 - 12:49 PM

 

Setanta that's the procedure if your metal detector fails a test.  He asked if the metal detector finds metal.
 
I asked what you make because the procedure can be different. 
 
In 2 of the factories I've worked in we packed a dry product so what we did was we pulled the failed product off of the line and then inspected the contents to find the piece of metal.  My current job is bagged flour so we have a stand alone metal detector we can pass the bagged flour through to find the piece of metal (50 lb bags).  The other one was pasta so they just opened the box and the operators spread the pasta out on a plate and looked for the metal.
 
If no metal was found then they inspected the packaging to see if the metal was there.
 
Then they fill out a form that has the results of the inspection.


Ahhhh, true that! OOOPS!

If we find metal, we take the product completely apart until the metal is found. Most times it is some part of the packaging that has the metal, cardboard, usually. We would replace the packaging, re-run the item, if it passes, let it go.

IF not, we disassemble the product until the metal is found. Then maintenance is involved to ID the piece. If it obviously stuck in another ingredient, we track that information. If it is a One-Off, something that rarely happens, we just track the data. If it is part of larger problem in house or from a supplier, we track this with a Corrective Action Report.

If there is a larger in house issue, we would stop the line if needed, to ID and repair the item

Setanta

Edited by Setanta, 18 July 2014 - 12:51 PM.

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Posted 18 July 2014 - 01:01 PM

I tell you what else I have done, is that I have passed various items through the metal detector, such as hair grips (bobby clips?), staples, drawing pins, anything I can lay my hands on, and then I've documented it all.

 

Because its a "salty" environment, I have also exposed these items to salt, seen if they corroded and repeated the exercise.

 

I also keep a log of all FB's found.

 

Caz x



Setanta

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Posted 18 July 2014 - 01:18 PM

 

I tell you what else I have done, is that I have passed various items through the metal detector, such as hair grips (bobby clips?), staples, drawing pins, anything I can lay my hands on, and then I've documented it all.
 
Because its a "salty" environment, I have also exposed these items to salt, seen if they corroded and repeated the exercise.
 
I also keep a log of all FB's found.
 
Caz x



We also keep a log, and we've run sample items through. I wanted to mention that we've tested the metal detectable bandages to prove that they are as advertised. :) 

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Posted 18 July 2014 - 04:25 PM

If a piece of metal found in the product by metal detector, what is the standard procedure to follow?

Dear ts33,

 

An equally short generic answer - Find the detected piece of metal, remove it, implement/document yr "immediate" corrective action portion for yr haccp-MD-CCP and start looking for the root cause.

 

Rgds / Charles.C


Kind Regards,

 

Charles.C





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