Manage a metal detector test failure

You are a Packing Operator on snack line 2 at Dandenong South.

Simulated workplaceEntry missionCAQA Orchard Lane Foods

What is going on

At the 1410 hourly test on snack line 2 the stainless steel test piece passed through the metal detector without being rejected. The operator stopped the line, placed all product packed since the 1310 passed test on hold and called the line leader and engineering. The detector was re-tuned and passed a full test at 1455. One hour of apricot and almond fruit bars is on hold in the quarantine area and the batch is on hold in the batch record system. Priya Nair needs the held product re-passed through the detector under supervision, the monitoring log completed and the non-conformance report finished so she can close the investigation.

Priya Nair, Quality Assurance Officer
Subject: Metal detector failure yesterday, held product and records

The stainless test piece was not rejected at the 1410 test on snack line 2 yesterday and one hour of apricot and almond bars is on hold. I need you to work through it as the operator: review the monitoring log entries, confirm the hold covers everything since the last passed test, re-pass the held product through the re-tuned detector under supervision, record the outcome in the log and complete the non-conformance report so I can finish the investigation. Read the metal detection procedure first and follow the test method exactly.

Your brief

Follow the metal detection procedure to confirm the scope of the hold, re-pass the held product through the repaired detector using the correct test method, record every step in the monitoring log and complete the non-conformance report so the batch can be reviewed for release.

Work through it

You do not need to do it all. Doing a few of these will show you what the work is like. Your ticks and notes stay on this device.

Read the Metal Detection Critical Control Point Procedure and write down the test frequency, the test method and the actions required when a test fails.
Review the monitoring log entries for snack line 2 on 8 September and confirm that the hold covers all product packed between the last passed test and the failure.
Perform and record a full three test piece test at leading edge, centre and trailing edge before re-passing any held product.
Re-pass the held product through the detector under the supervision of the line leader, count the packs re-passed, and record any reject and its examination.
Enter the re-pass result and the pack count in the Critical Control Point Monitoring Log and update the batch notes in the Production Batch Records system.
Complete the Non-conformance and Deviation Report Form for the test failure with containment actions, quantities and the re-pass outcome, and update the register entry.
Write a short handover note for the afternoon shift line leader describing the event and the status of the batch.

My notes: what did I enjoy, and what surprised me?

What someone in this role would produce

Monitoring log entries for the full test and the re-pass
Completed non-conformance report
Updated batch record notes
Shift handover note

Printing this is a record of what you explored. It is not a certificate or a qualification.