The metallic foreign bodies prevention program

This program is a part of the foreign body policy. But in this series the focus is oriented toward the metallic bodies. Which elements consist to minimize the metallic contamination?

• The maintenance of the machines – The regular maintenance plays a positive role. This is also applicable to the direct intervention in case of signs indicating broken or worn parts
• The preventive maintenance on risk full parts – The moving parts are subject to wear. Determining the technical life of these parts and organizing their preventive replacement frees you from contamination sources
• Removal of metallic bodies during the manufacturing process (through magnets) – The so called quick wins: The magnets already retain a lot of the initial contamination during the process. Above all it is practical for the bodies with a size below the detection limit
• Hygiene of the production areas and cleaning procedures – Taking care of a clean environment. Avoid round winding materials. Analyse where the cleaning process may cause problems (for example with loosening screws)
• The use of sieves and filters – Like on the magnet point. Everything which is removed during the process doesn’t pose a risk anymore. This is extra valid for the bodies which are smaller than the detection limit
• Maintenance procedures and machine breakdown – It’s about how the maintenance is performed. Consider the shielding and the protection of the production line, the line release procedure line after maintenance and after that, the verification of the used tools and materials
• Hygiene rounds and training of staff – A paper work system is a good starting point. However, hygiene rounds have to be carried out and the staff needs to be trained and sensitized in the implementation of procedures and good practices
• Supplier management – Analyse the existing risks at your suppliers and assure their good management
• Material management – The choices to make during the purchase of machines and materials. Use approved materials: robust, non-corrosive and resistant to wear
• Knife policy – Knives are a dangerous source of metal contamination. Inventory your knives and manage them with the knife policy procedure
• Spikes and screws – Spikes have no grip in the walls and so they don’t belong to a production environment. Screws are fine, but of the type which corresponds to your materials policy
• Direct analysis of rejected products – The rejected products should be analysed immediately, so that the corrective actions can be taken straight away
• Trend and cause analysis of the found metal bodies – Trend and cause analysis tools will allow you to take preventive actions and to reduce your metallic contamination
• Commitment of the staff – This puts the immediate response in case of problems into work. The signals will be picked up to and directly transformed into action