Thanks everyone! Update on the saga -
Hello Magenta. Here are my thoughts on this:
- Finally, you as a QA/FS manager must do the due diligence and follow the procedure to report and investigate the incident. Leave it all documented, but you are not a police or regulatory entity, so if your supplier deny having anything to do, don’t get to stressed about it.. And rather focus on more internal control.. Such as metal detector at receiving?
MM, you are in the lucky position of identifying a risk without incurring the full impact. You already identified you can't pin it down to one supplier or lot; I would drop the "catch" position and move on to "prevent recurrence".
Yes, now I'm onto corrective action and I've having a hard time ensuring it doesn't happen again. Both suppliers responded to ask about all lot numbers in the tank, which I provided, but did not return an investigation yet (I'm forgiving on this one - I'll give um more time). Assuming they provide satisfactory reports, I still don't have a lot going for me on the "prevent this from happening" front.
I've had some ideas and made a list of preventative actions, one of which was metal detector or x-ray raw materials. These are too large to fit through our current detector, so we would have to purchase an new one, which is out of the question. We already have a screen post melting pre tempering, but it is post Melting tank. We do inspect raw materials prior to using them, but because the block of chocolate is so large, there's no way to visually detect embedded FBs. I got frustrated so most of them are things like "Don't buy chocolate with metal in it" or "Purchase back up Chocolate Tank / Pump to use when metal destroys first one" or "Melt chocolate prior to melting tank" or "use log splitter to chip chocolate into tiny pieces then run it through a metal detector"
Contacting both suppliers is absolutely the way to go, but....
How do you know that this might not have come from someone in your plant - deliberately?
We have had incidents (years ago) when someone through a wrench into a tank. And not just once.
Do you have any way of knowing - like video surveillance - that someone didn't bring the tool from home and throw it in the tank?
We, too, use chocolate (receive in solid chip or block form and add to tanks). We empty our tanks for changeovers alot and so my feeling is that this FM entered your system very recently -- it's very unlikely that it has been in the tank for months.
Good luck -- hope you get the answers you need!
Agreed!You should also investigate/consider a self-check for possible acts of sabotage. Consider all possible reasons for contamination.
Now this is interesting -
Ah, we do have video surveillance. Is it unfortunate in that we do not *record* this footage (they only have cameras to violate our privacy and make us feel watched). Access to the top of the tank is already restricted to 2 floor employees, 1 of which is supervisor, and maintenance (plus inspections). We do tool inventory, and don't have pin punches or MAC Tools; I'm confident it didn't come from our factory, but maybe an employee's home? The initials on the Pin Punch don't match any of the employees with access to the tanks. I'm open to exploring this, but I'm not sure how exactly would one go about investigating if they were convinced it was an act of sabotage ? Employee interviews? Home raids of their garages? Compare names against list of suspected Communists? Fire them all and let God sort it out?
Threw a wrench in the works, eh?
To organize and teach, no doubt, Is very good — that's true, But still we can't succeed without The Good Old Wooden Shoe