Foreign Body Prevention

Module 2

Plastic, Rubber and Other Flexible

Material
Sonia Oliveira
NQAC Zone AMS
September 2014

TYPES
More than 40 types of plastic and rubber material have been identified in
factories (see attached worksheet). For the purpose of this document
purpose, the most common cases have been selected and grouped in the
following categories:

Rubbers and Silicon

Plastic bags
Packaging and auxiliary material
Hard Plastic - Process
Maintenance and office material

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ACTIONS MUST BE TAKEN CONSIDERING THESE THREE ASPECTS

Sources

Prevention
Monitoring

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Foreign Body Management

Guideline for classification of practices
observed in factories

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Under

Base

Emerging

High Performing

Rubbers and Silicon (1)

Source
Gaskets, orings.
Retentors

Prevention
Evaluation of needs
(is it necessary? Is it really
recommended? )

Filter checking

Chose of correct material (fit

for purpose)

X Ray (applicable just for

high density gaskets

Adequate cleaning method

Adequate replacement
Program

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Monitoring

Visual inspection (VS)

Gaskets Where are they really

needed?
The purpose of gaskets is to ensure perfect sealing in order to avoid leakage
and/or preventing contamination from the external area. Flexible
connections, frequently in dry process, play also a roll on leakage
prevention. Considering that, it is possible to evaluate the need for gaskets
on different parts of the line. The need is clear for piping, heat exchangers,
pressurized tanks and so on, but are they really necessary for all type of
tanks, hoppers, sieves and so on? This is what we challenge you to define,
based on the will be presented on the next slides.

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When there are gaskets, they

must be managed
But are they really necessary for all cases?
Protection or potential FB
inclusion or potential source of
FB?

If it is really necessary, must be

In good condition

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Gaskets Where are they really

needed?
If it is possible not
using it, then remove it

With (and loosing parts)

without

Ice Cream storage tanks: same factory, same

tank design, some have gaskets, others dont.

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Example from a mixer where the factory

concluded that there was no need for gaskets

Choosing the correct gasket

Various sources of foreign bodies have been from the breakdown of wrongly selected materials. In order to
reduce the risk of these compounds becoming foreign bodies it is important to select the correct compound for
each application.
The suitability of the compound will depend on many factors in the installation:
operating temperatures,
chemical resistance to the food and the environment,
resistance to ageing from light,
resistance to abrasion,
resistance to physical structure change over time.
EHEDG Doc- 32- Material of construction for equipment in contact with food

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GI-221.28 REDUCING FOREIGN BODIES BY PROPER HYGIENIC DESIGN

Using the correct gasket

additional recommendations
Gaskets provided with equipment like butterfly valve, flap of metal detector,
around vibratory sieve, etc. which open / operate frequently must be
procured from Original Equipment Manufacturer.

Shelf life of gasket must be confirmed from the gaskets supplier. Each gasket
must be replaced at the end of the prescribed shelf life.

FOR ADDITIONAL INFORMATION CONSULT EHEDG GUIDELINES

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Detectable gaskets
The use of detectable gaskets is useful for monitoring purpose. High Density
Silicon Gaskets can be detected by X Ray

Example of High Density Silicon Gaskets

for Milk Powder Line - Brazil

Regular gasket
Not detectable

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Density > Milk Powder

Gaskets installation

The gasket of the sight glass of the vacuum band dryer, evaporator, tank or
Egron can be damaged if not properly designed and installed and eventually
generate Foreign Bodies.

Pay special attention to the material of the

gasket, its size and insure the tightness by
using a proper hygienic fitting.

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Choosing the correct Cleaning

Method
As explained in the previous slide the type of gasket and cleaning method
must be compatible. Pay attention to that when defining the cleaning and
disinfection method.

Example of damaged gasket not, where material and chemical

were not compatible

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Gasket Mapping
Gasket Mapping is an important tool
for Foreign Body Management because it
is a guide for inspection and investigation

Prepare list of all

gaskets used in
production (type,
position, material,
size)

risk of breakage
Perform Gasket Risk Consider
and retaining points placed
Assessment
after the gasket.

Prepare Gasket
Mapping (indicating
the gasket positions
on the flow sheet by
using color code
according to the Risk

Low Risk
High Risk

Establish inspection
frequency and
replacement plan
based on risk

* Retaining Point: filters or sieves 2 mm

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RISK MATRIX & INSPECTION FREQUENCY :

Gasket Risk Assessment

I.

DICISION TREE :

A.

Subsequent control ( 2.0mm

sieve down the line)

Presence of fine filter / sieve down the line

which can arrest the piece of damaged gasket.

A Gasket Risk Assessment

Must be done in order to
define frequency of inspection
and replacement

Foreign body collected from those sieve / filters

are checked on shift basis
Gasket fitted upstream of that sieve will be
considered as Low risk

B. Position of gasket in
process flow
Presence of gaskets inside pipe line union, are
static gasket.
Gasket fitted inside butterfly valve, sieve which
operate more frequently and having manual
intervention are moving gasket

This is a good example from Nestle

SAR

Gasket fitted in moving conditions will be

considered as High risk

C.

Sl. No
1
2
3
4

Subsequent
filter of
2.0mm size

Risk of moving
parts
Yes
Yes
No
No

No
Yes
No
Yes

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Size of gasket
Size measurement is important for gaskets fitted
inside pipe line union / flange.

Risk rating
High
Medium
Low
Low

Inspection
frequnecy
Monthly
Quarterly
Yearly
Not required

Gaskets are to be procured from the original vendors who have

supplied the union.
In case of old lines and non-availability of original vendor, gasket is
procured from other vendor then at reception of gasket consignment,
take 30 samples from lot and measure the size (ID & OD).

Calculate co-efficient of performance (cp). If cp >1.3

then accept the consignment otherwise reject it.

Example of Gasket Mapping

Chile

Red: High Risk

Green: Low Risk

Graneros/CH
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Gasket Inspection productspecific instructions

Regular inspection and maintenance of
the gaskets especially the gaskets on
dry process e.g. dry mixing, tote bins
and tilting stations should be done at
each shift.

Inspection during Cleaning When dismantling line for COP,

check the gasket condition and
replace it if necessary.
Filling machine where any nondurable material, such as rubber
gasket, seal, lubricant, are used,
need to be maintained, changed,
and
checked with higher frequency
than other location.

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Standard for inspection and

replacement
A stock of most common gaskets used in the
factory must be kept, according to the
replacement frequency

People must be trained on how to perform

inspection and acceptance criteria.
It is important to establish a standard for
visual inspection in order to calibrate this
activity. For this purpose, visual standards
and OLP are recommended
Create VS

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Other Flexible Parts of

Equipment
Hoses

sleeves

For hoses and sleeves, the same recommentation made for

gaskets
can be applied
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Monitoring - Filters and

Sieves
Different types of FB can be monitored by checking filters and sieves

The operators must be trained to

identifiy pieces of gaskets and report
its presence

The detailled procedure for filter checking

will be described on the Topic about Monitoring

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Plastic Bags
Source

Raw Material
Packaging
Rework, Trash,
Residue bags

Stretch film

Prevention

Replacement by non
plastic material (when
choking is a risk, i.e
NN products)
Provide adequate tool
opening raw material
bags
Use of more resistant
plastic
Restriction of stretch
film usage

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Monitoring
Filter and sieve
checking
Visual inspection (VS)

Plastic Bags Raw Material

Most of raw material come in Big Bags or Plastic
Bags. These type of packaging can become a
source of foreign body due to bad quality material,
or closure system (hard to open bags) . In this
case, the supplier must be contacted for better
solution

Bad Quality Big Bag

Raw Material Packaging hard to

open and adhesive tape

Big Bag fibers

retained in the filter

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Mixing filters containing pieces

of raffia (from sugar bags)

Some pieces of raffia can pass

through the holes of the filter

23

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Options for Bag Opening

Work together with the Supplier on better solutions for Raw Material packaging (type of
material, shape, opening, etc.)

Examples:
Paper bags can be good options for dry raw materials
In case of large volume Check possibility of bulk supplying
(example: cocoa butter) or Big Bag

Review bag specifications with purchasing:

Favour easy opening bags using strings,
Information to the factories on how to open
the bags

Options for bag opening - : simple knives

Knife has to be made of single piece of metal and chained. Hexa blades with sharp
edges must not be used as knives.

Application: frozen and wet raw material

Positive Aspects
Holes are closed, so no hollow bodies.
Knifes are from stainless steal

Negative Aspects
Risk of injury
Need to change regularly to sharpen

Mitigation
Use knives with short blades
Store in designated and safe 5S locations
Knives should be numbered and controlled issue only on the return of old ones.

Source: Sevares Compliance Workshop July 2012 Zone EUR

25

Options for Bag Opening

Dry Raw Material

Paper bags can

be opened
without cutters,
by pulling
strings.
Define location at
arm length
distance for
waste, including
strings and small
parts of bags
(throwing distance
is not appropriate)

Example of Safe Cutters

Shiftily inspection for
missing parts.
Exchange of blades
and other pieces is
performed in a
controlled manner(log)
Most Hygienic

Most confortable

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Use of cutting tools for opening

cocoa butter

Opening by using hands higher

risk of plastic inclusion (plastic
pieces get stuck in the cocoa
butter)
27

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Stretch film
Stretch film is commonly used in factories for covering
packaging material, pieces of equipment and obsolete
(or not) in use equipment. This type of solution can
lead to Foreign Body issues, specially in areas where
product is exposed.

Prevention
Remove obsolete equipment from Production Areas
Do not store parts of equipment in Production Areas

Do not use stretch film in

areas where raw material,
semi-finished or finished
products are exposed. Prefer
caps or higher density plastic
covers (well maintained)

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Strech Film for Packaging

Material
Shrink film is preferable than
stretch film for glasses, cans,
plastic and bottles, but can be
wrapped too.

Care must be taken with plastic bags

used for auxiliary materials packaging

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Filters Retaining and

Monitoring
Filters can retain larges pieces
of plastic, but cannot be
consider a control measure for
choking prevention because
some smaller pieces can pass
through.

Residues of plastic and burnt particles found in filter

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Hard Plastic - Process

Source
Moulds

Prevention
For this specific issue
please refer to MI-33.032
Guidelines for the use
polycarbonate moulds in
manufacturing chocolate
Also use MI-33.040 /
11/2010

Foreign body prevention in

sugar confectionery
factories

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Monitoring
For this specific issue please
refer to MI-33.032 Guidelines
for the use polycarbonate
moulds in manufacturing
chocolate

General Recommendation
Confectionery moulds must be made only
from virgin polycarbonate to avoid any
possibility of contaminants that might render
them unsuitable for food contact, or reduce
their strength. Color must be added to
make any broken pieces visible and look
less like glass

Mould washing chemicals must be

supplied by one of the following:
Ecolab
Johnson Diversey

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Mould Washing
Incorrect washing of moulds can destroy them in a matter of weeks.

Mould washing equipment must be regularly checked and kept in a

good state of maintenance according to manufacturers guidance;
therefore mould washing must be carried out by Nestl personnel
appropriately trained on quality and food safety aspects.

Insert picture

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Mould inspection

Moulds are preferably stored in cages where each mould has its own
compartment. Cages must not have wire mesh floors as these will damage
the moulds.
A record must be kept of the number of hours of production use and the
number of wash cycles for each mould set.

Regular inspection of moulds is mandatory for early detection of potential

problems. The best inspection point is after the mould washer where the
moulds are individually handled and clean, making damage more visible
(minimum weekly). If the moulds are not washed at least weekly, a procedure
must be in place for inspection in line (ex. after demoulding). Establish
standards for acceptance criteria and implement monitoring plan. Best practices
include Mould inspection on the Sector Quality Pyramid a/or SHO.
New mould sets must be carefully inspected before acceptance.
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Process
Moulding plant set-up and maintenance are critical steps
Incorrect running conditions on the line can lead to mould jams and stickers
(products that have not demoulded).
Impact during demoulding can lead to damage, so care must be taken during
this step.
Scrapers and licking rolls are needed to clean mould surfaces. Older types can be
troublesome and cause damage.

The physical condition of chains, and that of the tensioning system,

is critical to the good operation of the plant. Chains maintenance
and inspection.
Moulds must always be cooled before being put onto the plant;
when warm they can expand sufficiently to jam the line.
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Hard Plastic - Process

Source

Parts of
Equipment

Prevention

Map of hard plastic,

retaining and detection
points (see Gasket
map)
Hard Plastic Risk
Assessment (see
procedure for gaskets)

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Monitoring

Inspection
Program
Filter and Sieve
inspection
X Ray Rejection
inspection (where
applicable)

Parts of equipment - Hard

plastic and conveyors

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Parts of equipment - Hard plastic

and conveyors
Similar to the procedure recommended for gaskets, all the plastic sources in equipment (hard
or conveyors must be mapped. Special attention must be given to steps where there is
higher risk of inclusion as: melted chocolate, biscuit before baking, chocolate and biscuit
filling, prepared food, powder and liquid.
Use appropriate material. Perform management of changes when acquiring new material. Is it
adequate for the purpose?
Identify points of retention after the Foreign Body source (consider sieves and filters < 2mm).
Implement preventive maintenance and inspection for risky points.
Attention must be given to cleaning procedure. Some chemicals are incompatible with some
plastic material - check it with the material suppliers.

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Packaging and Auxiliary Material

Source
Soft Laminated
packaging
Hard laminated
packaging

Bottles, Cups and

Boxes
Scoops

Prevention
Supplyer Program
development

Blower rejection checking

Visual inspection (VS)

Visual Inspection
Quality Pyramid
Adequate storage before
usage
Blower
Adequate procedure for
termoforming packages
Adequated Procedure for
unrwapping (rework)

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Monitoring

Scoop and taps

Scoops and taps can be a source of different FB types,
as plastic fragments, hair, insects and dust. So the main
action is acquiring material from reliable suppliers.
Vendor People will be very helping on developing and
auditing.

Besides, some
actions can be taken
in the factory

Dont let package and auxiliary package

material open in the warehouse or
unprotected in the production line.

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A blower System with deionized air is

recommended for direct contact package or
auxiliary material that go inside the product.
Where a blower system is not in place, an
inspection procedure is recommended.

Blowing System to Clean cans

and Bottles
Blowing with ionized air for FB removal
Before filling, the cans/bottles must be cleaned, even when these are coming directly from the
can/bottles (*) making line to the filler. It is important to consider the velocity and the size of the cans to
determine the system configuration. In addition, air blowing unit and air suction are mandatory. Ionized
air (dry and oil-free compressed air) must be used in the can blowing system.

The specifications are provide in product-specific GIs, according to the Product:

MI-07.086 / Foreign Body Management Program for Nestle Nutrition Baby Meals and Drinks
Manufacturing Locations
MI-08.717 Foreign Body Prevention Tool-Kit for Dairy & Nutrition Powder Factories

(*) Bottle Supplier plant inside the factory

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Rework package fragments

Presence of packaging fragments are common in consumer complaints, but can
be avoided by applying some practices. There are two types of rework (bulk) and
packed product
Packed product unwrapping should not
be done close to exposed product or
semi-finished. It is recommended to
perform this task in a specific area for this
purpose

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Rework package fragments

When removing package or rework from bags, care must be taken to avoid
contamination with pieces of plastic. Establish procedure for this activity and
perform it in under proper lightning
Melted and powdered rework must be sieved in a 0.4 to 0.5 mm sieve, to avoid
pieces of package and.
Colored (non toxic) rework bags are
preferable than white transparent because
pieces of plastic become more visible.

Pieces of package must be disposed in appropriate container/bags. Clean the

rework area after use (do not leave pieces of package, package shavings on the
floor.

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Shavings in thermoformed
packages
Piece of Polystyrene (from the own pot) can be found inside the product and
lead to consumer complaint. This type of FB is a shaving produced during
cutting, after filling and sealing. Usually these shavings usually fall down in
a collector, but when cutting tool is not properly sharped, some piece can
get stuck on the external side of the pot, falling on the next one.

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Maintenance material (most

common FB sources)
Source

Cable ties
Adhesive tape
Other
maintenance
material
(fragments)

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Prevention

Monitoring

Good Hygienic
Engineering Practices
Fit for purpose
material

Detectable material

NGMP/5S
audit

Cable ties
Pices of cable ties can easily reach product, when
become dry, break and are lounched far.

Broken cable
ties found on the floor in
High Hygiene Area. Metallic
tightner is a better option for
areas warmer areas (ex.
Egron Towers)

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Very short cut. Higher

possibility of getting loose.

Detectable ties can be an option

For areas where unpacked products, raw
material and semi-finished product are
exposed

When found in products, pieces of white

cable ties are frequently mixed up with teeth
and nails by consumers

Adhesive tapes
Adhesive tapes are used as temporary solution to
fix leackage. Sometimes, temporary becomes
permanent. Why?

Overpreasured line;
Damaged torn flexible connections;
Frequent blockages;
No time to fix the clamps, hence easy solution to
use tapes;
Bad quality clamps for flexible connections;
Not enough stock of flexes and clamps;
Mechanic not always available to fix the clamps;
Surface on equipment not smooth enough to
ensure leak proof fixing of clamps.
Lack of maintenance

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Maintenance material
General Prevention

Do not carry out major maintenance on

wrapping machines while other machines
nearby are in operation.

Isolate the machine under repair to ensure

product is safe from any contamination.

No major maintenance without proper isolation.

Do not loose tools during maintenance that

could become a source of foreign bodies.

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Do not make temporary fixings.

Temporary fixtures should be repaired.

Clean the area thoroughly after

maintenance. Do not use compressed
air for cleaning, as it spreads small parts
like pieces of wire and plastic.

Follow line release system by a joint

team before and after maintenance.

Zero tolerance for indiscipline

Set tools inventory, use check list to

release the lines after maintenance

Keep tools under control always.

Toolbox under inventory control and
check list

What must be done

Engineering must be involved for the

permanent solutions of leakages

problems.
Commitment from all against the
tape culture in the factory

Pay attention to lines that carry fine

powders as raw materials, cocoa,
milk powder, flour or liquid product .

Basic DMAIC for problem solving

Temporary fixtures should be
repaired (with correct design)
during next cleaning cycle.

Include tape hunting in periodic plant

visits, internal gap assessments etc.

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Implement AM pillar of TPM.

Miscelaneus

Source

Prevention

Cleaning tools

Use of good quality

material, inspection,
adequate
replacement
program

Plastic
containers
Safety signing

Pens

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Housekeeping/5S

Police on use of pens

in production lines

Monitoring

NGMP/5S
audit

Cleaning tools
Industrial tools with Hygienic Design are recommended.
When these type of tools are not available in the Market,
suppliers can be developed, but care must be taken on
quality and color coding.
A procedure for inspection and
replacement must be
implemented. Establish
acceptable conditions by means
of VS.
Temporary solutions for repair
are not recommended.

Poor material and no

program for inspection/
replacement in place

Example of good
Quality tools: USA
and Guatemala

Correct use of cleaning tools

Do not use brushes as temporary
hammers to clear line blockages.
Do not use brushes as scrapers to remove
hard residues from equipment surfaces.

Do not use the same design of brushes for

every cleaning application. Involve brush
suppliers to design the right tools for
different purpose.

Do not you use sponges and other similar

materials which can be a source of foreign
bodies.

More about Cleaning tools

Bristles of brushes are plastic;

they become brittle and hard
with extreme temperatures.

Cleaning and drying conditions

should also be monitored.

1.

Temperature of hot water max

45C.

2. Temperature of drying max 60C.

Manufacturer
recommendations for
cleaning and drying
must be respected.

Pens
Pens are still largely used in
some factories and can
become a source of Foreign
Body

Loose ball point pens are banned in any

processing areas (dry & wet).

Inventory of items representing a potential

FB risk (e.g. pen, ear plugs, goggles, etc.)
has to be maintained in each processing
area.

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Pens

Any pen necessary must be attached to the

working station and x-ray/metal detectable.

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Pens used for Operational

Review Meetings must be placed
at the board and be controlled

Safety signing
Safety Signing tapes, identification tags and
anti slip tapes can become sources of
Foreign body if not proper maintained.
These material must be restricted to the
intendend use without excess, be regularly
inspected and replaced.

Good example of painting instead of tape, but

maintenance is still required - USA
CO-QM

Anti-slip tape loosing

parts (close to raw
material tipping)

Plastic boxes
Used for different purposes,
plastic boxes can become
sources of Foreign Body if not
in proper conditions
Establish procedure for inspection and
replacement.
Purchase resistant
material, according to
the purpose

Keep enough stock for

replacement

Good example of resistant

covered boxes - Guatemala

Monitoring Details

Filter and
Sieve
inspection

CO-QM

Collecting
Boxes

Quality
Pyramid

Filters and Sieves

These equipment provide good information on Foreign Body Sources and can
be used as sampling/monitoring points.

Filters and sieves must be well

maintained e frequently cleaned to avoid

The frequency of cleaning must be

established case by case. Remember
that the source must be eliminated or
reduced

Plastic retained in a filter 4 hours after

cleaning.

Filter and Sieve Inspection

Open the filter and perform a first examination, looking for plastic or any
kind of FB
Register what you find in a worksheet.

For more detailed examination, collect the filter content in a plastic bag
(identified with place, date and time) and take to the lab or other
appropriate place.
Pass the contact through a sieve (0.4 0.5 mm).

If you are also searching for metal, use a

magnetic bar.

Example of Procedure for Filter Inspection

1323.IL.FAB2.18-004 LIMPEZA - INSPEO DOS FILTROS APS OS TERLETS - ANTES E APS CIP
EQUIPAMENTO:

LINHA:

Nmero de pessoas:

Tempo da Atividade:

Frequncia da atividade:

FILTROS APS OS TERLETS

REQUEIJO

1 pessoa

30 minutos

Antes e aps CIP

EPI - Equipamento de Proteo Individual

Operador

Auxiliar qualificado

Ferramentas Necessrias:

Proteo da Mquina

Referncia do Documento:

Responsvel pela execuo:

GI 31.100 - Boas Prticas de Fabricao.

GI 31.123 - Validation of the effectiveness of
cleaning.

Dispositivos Necessrios:

N/A
Protetor
auricular

culos
ampla viso

Avental
Luva
nitrlica

Botas
Plsticas

1
Filtro
rodando

Balde
branco

Bandeja branca

Esptula de
metal

Chave de cano

Balde com nova soluo de

gua e detergente
Bucha verde
concentrao de 1,0 2,5%
NOVA

Mangote
gua fria

Filtro
parado

Antes do CIP fazer inspeo

no filtro que est rodando. O
outro j foi inspecionado na
troca de filtro.

N/A

A linha deve estar cheia de

gua. Fechar o registro de
sada do filtro que estava
rodando.

N/A

Colocar um balde
embaixo do filtro. Fechar
o registro de entrada do
filtro.

Soltar a conexo de
entrada com o auxlio 1 minuto
da chave de cano.

N/A

14
10

Soltar parcialmente a
conexo de sada do
filtro.

Desrosquear a
abraadeira.

N/A

11

12

1 minuto

GUARDAR O MATERIAL
ESTRANHO
ENCONTRADO EM UM
SACO PLSTICO.

O filtro ir sair da capa

e cair no balde.

13

N/A

Apertar as conexes
de sada.

1 minuto

Tirar a borracha removvel da

extremidade. Raspar as
2
incrustraes do filtro
minutos
apoiado na bandeja com a
esptula.

14

Apertar a conexo de
1 minuto
entrada.

Remexer a massa
atentamente em busca
de algum material
estranho.

15

Se for encontrado algum

material estranho: avisar e
entregar ao apoio ou na
SHO.

2
minutos

Abrir o registro de
sada do filtro.

16

Abrir o registro de
entrada do filtro.

N/A

Enxaguar o filtro com a

mangueira. Enxaguar a
1 minuto
borracha e recoloc-la
no filtro.

N/A

17

Antes de iniciar o CIP, abrir o

registro de sada do outro
filtro tambm.

N/A

LEGENDA:

18

Abrir o registro de entrada.

Os filtros esto prontos para
o CIP.

N/A

N/A

PROCEDIMENTO DE ALERTA:

ATENO

SEGURANA

PC

PLANO DE CONTROLE COM REGISTRO

QUALIDADE

CRITRIO DE APROVAO

PC

PLANO DE CONTROLE

Descrio da Modificao:

Em caso de anormalidade chamar o responsvel ou o apoio de

linha.
Aprovao:

Emitente
Elaborao do Documento.

N/A

Recolocar o filtro na
capa e recolocar a
abraadeira.

Visto:

Chefe da Fabricao
Visto:

Pgina(s):

Segurana

Qualidade
Visto:

Visto:

1 de 3

Foreign Body Management Program

Treasure
box

Collecting Box
Some recommendations:
About Collecting boxes
Must be small and locked, with a small opening for insert the objects
Identified by number
About materials
Collect the following materials: metals, hard plastic, glass, wood, lose maintenance packaging
material (if not belonging to the sector)
Associate the finding with a form, indicating, place, date, responsible and possible origin (if known)
About management
Follow the findings by boxes (most recurrent type of FB x box number). Establish target: %
findings/investigated

62

Example of Quality
Pyramid for Filling Areas
Promoting BBQ culture by using Quality Pyramid
at SHO in shop floor
Quality Pyramid
Proposed example for processing area
Consumer complaints referring to
hair and plastic

Near miss related action

A = hair on floor or cloth
B = re-training of roller tape using
C = pieces of packages on the
floor

Annex
1-

Standard action
A = nr of defective packages
(hard plastic)
B = Proper use of lint roller
C = Product opening for
reworking done according to the
procedure
CO-QM

1
2
3

Example of Pyramid related to

plastic & rubber
Indicators cascading (example for
basic factory)
Indicators

Based on NN QA pyramid on foreign body

management, at least the following indicators are
expected to be reviewed:

MOR

Consumer Complaints Foreign Body

WOR

DOR

FB findings / Total last sieve prior filling

Training on foreign body management

Visual inspection accuracy

Alignment HACCP / QMS / SAP

CO-QM

SHO

X
X

Training
Material got from the collecting
boxes, consumer complaint and
hunting activities can be used for
training.

CO-QM

Sources
Nestle Instructions
MI-07.086 - Foreign Body Management Program for Nestle Nutrition Baby Meals and Drinks Manufacturing Locations
MI-33.032 Standard for the use of polycarbonate moulds in confectionery manufacturing
MI-33.026 Foreign bodies prevention in chocolate and confectionery factories
MI-08.717 Foreign Body Prevention Tool-Kit for Dairy & Nutrition Powder Factories
MI-07.086 Foreign Body Management Program for Nestle Nutrition Baby Meals and Drinks Manufacturing Locations
Minimum requirements

Quality Near Missing/Briefs

Torn Rubber Sleeve of weighter silo inlet pipe

Gasket Material Found In Infant Formula
Foreign Body: Ball Point Pen
Kit Kat 2 fingers chocolate with hard plastic foreign bodies
Nestle chocolate with moulds pieces
CRUSTINI (Hot Pocket) with pieces of plastic belts
Fitness and fruits breakfast cereal with plastic pieces

Photos
Briefs and Treasure Hunting Exercise

sonia.oliveira@br.nestle.com
fernando.ubaran@br.nestle.com