12 replies to this topic

[yvo]

Chapter 6.1.5. Sharp control

How is that best set in place? Should sharps be registered and marked with personel number and then after being thrown in a specified container regulary be counted?

Or should the sharps be not-personal, but registered when incoming and outgoing. But what is done in case one blade is missing? When we mark with personal number we at least would know who to ask. As we use in our factory many blades that may be frequently the case.

How do other companys handle that matter?
Thank you for any idea or experience!
Yvo Duerr

[Charles Chew]

Hi Yvo,

Its a nice topic. Try to refer to one of the sections which I think is in the document exchange section. There is a good example document sent in by Simon on BRC control documentations.

My experience in this area (with food) is you do not really need to identify the sharp object (say blade) with the user person. However, each user must sign in when a blade is issued to him and consequently sign out when the blade is returned. That confirms the issuuance control and return accountability.

However, the task is not complete if the remark section is not fulfilled. The blade should be checked as well so that it is returned in good condition AND in ONE PIECE. Broken blades are often the danger rather than the blade itself.

TIP: Do not use "breakable/disposable blade type" but rather those with fixed unbreakable blade as in a utility knive.

Hope this helps, Yvo.

Regards
Charles Chew

[Simon]

Hi Yvo,

Welcome to the forum. Well Yvo it's all about control and numbering the knives and issuing them to individual personnel will give you better control.

Like Charles said fixed blade knives are good. You can also get changeable blade knives such as the ones in this picture.

 Knives.jpg   20.81KB   188 downloads

The top one is a foldaway penknife, the middle one is a manually retractable scalpel and the bottom one is an automatic retractable. All are good, as they do not have snap off blades. As you can see the knives are engraved with a unique code. Personnel can be issued with a knife, which is then their permanent responsibility. The knife issue can be recorded on a master knife issue list like this attached example:

 knife_issue_record.doc   9.76KB   845 downloads

When a new blade is required the operator takes their knife to a Supervisor and they change the blade and this can be recorded on a document like this attached example:

 Blade_Control_Record.doc   50.5KB   567 downloads

If the blade is lost or damaged then there must be a review and details can be recorded on the backside of the above document.

Such a system may seem like a lot of hassle but it is relatively straightforward to set up and provides a high degree of control in terms of management and safety of the product.

Some further good practice points to consider:

- Do not allow operators to bring in their own knives
- Specify the type of knives to be used (don't forget to sample the operators first)
- Do not allow operators to take their knives home
- Provide sharps bins for blade disposal
- Provide some training or at least an explanation of the requirements to operators
- Add to GMP Audits (Are their any blades/knives lying about? Any uncontrolled knives?)
- Purely from an Health & Safety point of view you wouldn't want sharp objects left lying around on machinery or equipment.

Hope this helps.

Regards,
Simon

[yvo]

Many Thanks Charles and Simon for the replies!

I rather agree with Simon that we will number the registered knives and make them personal. Thereby we prevent from one worker suspecting the other to have taken his knive, and we have better control.

Well we will implement that concept soon and I can share our experiences later.

Best regards,
Yvo

[Simon]

Well we will implement that concept soon and I can share our experiences later.

<{POST_SNAPBACK}>

That would be really nice Yvo. If you need any further help please do not hesitate to ask. :D

Regards,
Simon

[yvo]

Well, we are now quite ahead with our sharp control and it seem to work. I however have to confess that we excluded two kind of blades from control.

By a risk assessment we found that first scissors are out of concern, because they are very unlikely to brake. Also the knive shown in the foto (see attachment) was not included. It is needed to cut foil but it is nearly impossible that the blade falls out or brakes. And in case the whole knife would fall in the products it is very easy to detect.

Does anyone disagree with that?
Best regards,
Yvo

Attached Files

•  knife_uncontrolled.jpg   60.33KB   108 downloads

[Charles Chew]

Yvo,

Glad to know yr blade control is working

I must confess too that I have one of these at home that I use for opening letters
Hmm! foil, i guess it should work as well. By the way, anything that can be fixed onto CAN be unfixed...........even welded joints of stainless steel process pipings break apart. Good to be cautious

CharlesChew

[Simon]

By a risk assessment we found that first scissors are out of concern, because they are very unlikely to brake. Also the knive shown in the foto (see attachment) was not included.

<{POST_SNAPBACK}>

Hi Yvo,

You've assessed the risk and if your team determine the likelihood of occurrence to be extremely low, then who are we to argue.

You should be OK.

Regards,
Simon

[shivendratripathi]

Dear Simon,

We are into Flexible packaging and find extreme difficulty while cutting laminate with scissors or knife. We are into an approach wherein the blade piece although removable is under the control of supervisors ie only they can issue these pieces. While issuing we maintain no records. Whenever these pieces break the supervisor asks for these broken pieces if found then a new piece is issued. If not found then a detailed investigation form is filled up.

What do you think? Will this suffice?

regards

Shivendra

[Simon]

We are into an approach wherein the blade piece although removable is under the control of supervisors ie only they can issue these pieces. While issuing we maintain no records. Whenever these pieces break the supervisor asks for these broken pieces if found then a new piece is issued. If not found then a detailed investigation form is filled up.

<{POST_SNAPBACK}>

It's important you have control of sharp cutting instruments. You have a system and if you believe you have 'control' without the need to document the issue and return of blades then it's up to you. However, if issues are not recorded how would the Supervisor know if there was a loss?

Regards,
Simon

[dwade]

Hi

We are having our BRC Audit next Friday Aaaah!!

With regards to knife issue. I have 2 people where I have issued knives as they use them day in day out. I have an issue where we normally have a floating knife for anyone to undo boxes etc if need be.

Can I have a floating knife under these circumstances if I register on the master knife control record.

Debbie

[MartLgn]

Hi

We are having our BRC Audit next Friday Aaaah!!

With regards to knife issue. I have 2 people where I have issued knives as they use them day in day out. I have an issue where we normally have a floating knife for anyone to undo boxes etc if need be.

Can I have a floating knife under these circumstances if I register on the master knife control record.

Debbie

Hi Debbie.

If the knife is listed on the blade register then it should be subject to the same controls as the other knives, how about issuing the general knife to an apointed person like a supervisor or line leader who can 'lend' it to people who need it and keep it in a suitable place? If your site can manage with so few knives then thats brilliant from a controllability view point.

Im sure you're aware but snap off type blades are a total no-no.

Best of luck for Friday, let us know how u get on

[Simon]

Best of luck for Friday, let us know how u get on

Fingers crossed for you Debbie.