Can Inspection Process Documentation

7.1.14.
1
PROCESS CONTROL REQUIREMENTS - CANS

12/8/03
Doug Pyer (Date)

12/15/03
(Date)

PALLETIZER

Finished Can Evaluation at Palletizer

Frequency of Check:

Continuously record defects 50 random cans per hour as cans enter palletizer. Refer to
Administrative Section Requirement for Visual Defects.

Gauging and/or Test Apparatus Used:

Visual inspection.

Data Retention (Forms For Recording Results):

Local Enter defects into quality monitor visual defect attribute database.

Internal/Customer Specification:

Inspection and Test Methods:

Inspect cans for visual defects. Refer to Requirement Procedure for Visual Defects located
under Administrative Section. Operating Specifications: Pallets are to be held under following
conditions:
A. One or more Critical or Major structural defects.
B. Three or more Major aesthetic defects.
C. Six or more Minor defects.
Implement C/A when the above criteria is met.

Safety:

Use appropriate safety gear which can include safety glasses, ear protection, apron, gloves, etc.

SOPs / Best Practices (As It Applies to Inspection):

Refer to SOP for Handling Critical Defects on Page 4.3.1.1 - 5.

Six Sigma:

(What Tools Used / Gauging or Process / Minimum Performance / Critical to Function)

Training Available:

Initiated By 11/5/07
Reviewed/

Revised By 11/18/11
Marlowe Wicks
(Date)
J ohn Rivard (Date)

By 11/5/07 Approved By 11/18/11
Sr. Mgr. WCP/Quality
(Date)
V.P. WCP/Quality
(Date)

Printed Copies Are Not Controlled
3/12/09

7.1.14.2
(Date) (Date) Doug Pyer
By Approved By 12/15/03
(Date) (Date)
V.P. WCP/Quality

J ohn Rivard

Marlowe Wicks
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PALLETIZER

Metal Exposure

Frequency and Sample Size of Check:
12 cans per hour for Manual Gauging

24 cans per hour with Automatic Gauging, Trac or 2+Sencon Auto ER.

1. G-1 114 Sencon Enamel Rater Gauge M#S I9000+
2. Waco Enamel Rater
3. Sencon QA2600 Automatic Metal Exposure Gauge
4. Trac 3999 Automatic Metal Exposure Gauge
5. RED Electrolyte Solution. Refer to Plant Lab Tests, Test B-1 1, for
preparation of the electrolyte solution.
6. Copper Sulfate Solution. Refer to Plant Lab Tests, Test B-1, for
preparation of the copper sulfate solution.
7. RED Enamel Rater Solution Material: #CCS002B - Red Enamel Rater
Solution. (200liter/drum) for the automatic enamel raters should be
purchased from:

Aqua Solutions, Inc vendor 1258200
Deer Park, TX 77536
Ph 281-479-2569
Fx 281-479-2720

Local or Computer


Beverage and Hot Fill 12 or 24 can sample

15 ma individual / 2.0 ma average internal spec.

25 ma Individual / 5.0 ma average customer spec.
7.1.14.3
(Date) (Date)
V.P. WCP/Quality

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Marlowe Wicks
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PALLETIZER

Metal Exposure

Internal/Customer Specification: (Contd.)

Beer 12 or 24 can sample

99% of the readings less than 50 ma, no more than 1% of the
readings greater than 50 ma and less than 75 ma (2 of 24 cans and
1 of 12 cans), and no readings greater than 75 ma Individual / 20
Average internal spec.

99% of the readings less than 50 ma, no more than 1% of the
readings greater than 50 ma and less than 75 ma (2 of 24 cans or 1
of 12cans ), and no readings greater than 75 ma Individual / 25ma
average customer spec.

Azo Dye, Export, and Energy Drinks 24 can sample

10 ma Individual / 2.0 ma Average internal spec.

25 ma Individual / 5.0 ma Average customer spec.

Note: There are 7 remaining FD&C food dyes used in the United States. Six of these
are used in beverages. These are (Red40, Blue1, Blue2, Green 3, Yellow 5 & 6). There
are only 3 that are a member of the Azo Dye Classification that are used in beverage
making. These are Red 40, Yellow #5 and Yellow #6. Those cans which have any one
of these dyes listed as an ingredient are a member of the azo dye classification. This
list is not exclusive of any dye that might be used with Azo Dye products, but these are
some of the dyes that are most commonly known as dyes that will cause an aggressive
content situation.

Inspection and Test Methods: Please note the inspection plans illustrated in the charts
that follow.

Manual Gauges Only

Gather 12 cans per hour at random when running beer, beverage, or hot fill.

Gather 24 cans per hour at random when running aggressive contents.

Measure 1 can per pin and plunger once every 6 hours twice per 12 hour shift,
once per 8 hour shift. This check can stand in place of the normal hourly
check.
7.1.14.4
(Date) (Date)
V.P. WCP/Quality

3/6/12/7/1
09

J ohn Rivard

Marlowe Wicks
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7/1
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3/
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PALLETIZER

Metal Exposure

Inspection and Test Methods: Please note the inspection plans illustrated in the charts
that follow. (Contd.)

Traq Gauges or Multiple Sencon Automatic Gauges

Gather 24 necked and flanged cans per line from the discharge of the Necker to
the Palletizer per hour and check for metal exposure with the automatic enamel
rater gauges. Insure that all machines are represented in the sample when
running aggressive products. Cans can be taken at random when measuring
beverage, beer, or hot fill.

Measure 1 can per pin and plunger once every 6 hours for two times per 12
hour shift, 1 time per 8 hour shift. This check can stand in place of the normal
hourly check.

Failure Reaction All Gauges

Initiate the AQL Procedure. If the problem is LSM related pull 24 cans from
the problem machine. If the problem is not LSM related, then quarantine
pallets with the suspect cans and perform the 96/100 can AQL. For each
occurrence of High ME a Metal Exposure Investigation Checklist (See 1.7.1,
2, 3) is to be completed and retained with cross reference to recorded ME
reading.

Note: in order to classify a defect as LSM related, one must first sample the
pallet using the 96/100 can procedure, and if all failed cans are from one
particular LSM, then all other pallets held for this defect can be designated
an LSM related defect.

Record of All Readings Above 8 ma

Note:
Check all cans over 8.0 ma for the source of the exposure using copper sulfate
solution, Plant Lab Test G-68. Log the results of this test into a spreadsheet
noting the date, time, line, machine, label, customer, and the reason for the
failure. Examine this spread sheet for patterns and trends.
7.1.14.5
(Date) Doug Pyer (Date)
Marlowe Wicks
3
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/7
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/
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1
0
0
9
(Date)
(Date)
V.P. WCP/Quality
3
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/09

PALLETIZER

Metal Exposure

1. Sampling plan for plants with No Complaints within past 6 months and when
running beer, beverage, or hot fill.

Palletizer: 12( manual) or 24 (automatic) random cans per hour. Sample by
gun is optional so long as the 24 can sample size is maintained.
Palletizer: 1 can per Pin and Plunger twice per shift. This check takes the
place of the 24 can random sample.

Beer, Beverage, and Hot Fill (Manual gauge 2 cans per gun and 12 cans at the Palletizer)

Frequency
(Hour #)
LSM / IBO
24 Random can
sample

Gauge

Palletizer

Gauge
1 6 cans / LSM Gun Manual 24 random cans Automatic
2 24 cans / Line Automatic 1 / Pin&Plung Manual
3 24 cans / Line Automatic 24 random cans Automatic
8 24 cans / Line Automatic 1 / Pin&Plung Manual
11 24 cans / Line Automatic 24 random cans
Automatic

Note: If the plant decides to pick at random, they must realize there is a risk
that all LSM guns will not be sampled every can check.


R Re ev vi is se ed d B By y

J ohn Rivard

6/7/10

3/12/09
7.1.14.6
(Date) Doug Pyer (Date)
(Date) (Date)
V.P. WCP/Quality

J ohn Rivard
Marlowe Wicks
Re
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/
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ReRevvisiseedd

6/7/10

3/12/09
3/
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3/
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7/1

PALLETIZER

Metal Exposure

2. Sampling plan for plants with leakage within past 6 months and when running
aggressive content products.

Palletizer: 24 cans every hour except the 2 hours when measuring the pins and plungers
while running aggressive content products on manual and automatic gauges.
Palletizer: 1 can per Pin and plunger twice per shift. This check replaces the 24 can
random sample
If using manual gauges only, the test rate is 24 cans per line per hour at the Palletizer. The
6 can per LSM test remains the same.

Aggressive Product Content (Manual gauge 2 per gun and 24 at the Palletizer).

Frequency
(Hour #)
LSM / IBO Insure
all guns are
represented

Gauge

Palletizer

Gauge
2 24 cans per Line Automatic 1 / Pin&Plng Manual
3 24 cans per Line Automatic 24 random cans Automatic
8 24 cans per Line Automatic 1 / Pin&Plng Manual
11 24 cans per Line Automatic 24 random cans
Automatic
All LSM / IBO checks should be verified that all guns are represented
with aggressive contents.

7.1.14.7
3
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PALLETIZER

Metal Exposure

3. Sampling Plan for Out of Specification Readings Acceptable Quality Level Testing or
Recheck Procedure

On any given production lot that has not passed the internal specification limits, the suitability for
shipment may be determined by using the following sampling plan or AQL (Acceptable Quality
Level). This procedure uses beverage specifications in the following description:

The AQL or recheck procedure allows for two different sample sizes. If the problem is related to
a particular LSM Gun beyond a shadow of doubt, a 24 can sample from that LSM Gun is the
correct sample size. This needs to be pulled from the pallets that contain the affected
product. If there is a problem found that is not related to the LSM Gun; i.e., Washer DI Rinse
not working, deco mandrel grease, varnish slings, etc., then a 96 / 100 can AQL must be pulled
from the affected product.

Note: in order to classify a defect as LSM related, one must first sample the pallet using the
96/100 can procedure, and if all failed cans are from one particular LSM, then all other
pallets held for this defect can be designated an LSM related defect.

If the original sample that was out of specification was greater than 15 but less than 25 ma and
the average is less than 5.0 ma, then that pallet can be resampled. When the cans are
measured, all cans are less than 25.0 ma, and the average of the sample does not exceed
5.0 ma; the pallet is acceptable for shipment. Samples should be selected from the top,
middle, and bottom from the narrow sides of the pallet.

If the original sample that was out of specification was greater than 25 ma or the average was
greater than 5 ma, then that pallet must be resprayed, reworked, or scrapped. When the pallet
containing the defective can is located, then the current pallet plus the previous 2 pallets and the
following 2 pallets must be retained as a lot of 5 pallets total. If the original failed can has a
reading >15 and <25 ma, it can be resampled. If the original test pallet had a reading greater
than 25 ma, it cannot be rechecked and found to be good. That pallet must be resprayed,
reworked, or scrapped, and no resample of that pallet can change that disposition.



J ohn Rivard

6/7/10

3/12/09
Doug Pyer (Date)
Marlowe Wicks
(Date)

By 12/15/03
(Date)

Approved By

V.P. WCP/Quality

3
6
/1
/7
2
/
/
1
0
0
9
(Date)
7.1.14.8
3
6
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/
1
7
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/1
/09

PALLETIZER

Metal Exposure

3. Sampling Plan for Out of Specification Readings Acceptable Quality Level Testing or
Recheck Procedure (Contd.)

The sampling plan must be implemented on the total lot of 5 pallets when the specification has
been exceeded. If one of the additional 4 pallets of the 5 pallet lot exceeds the specification
limits, the entire lot of 5** pallets must be resprayed or scrapped. If high metal exposure is
found on any of the previous or latter 2 pallets, then additional lots of 5 pallets must be
quarantined and sampled until all pallets meet the required specification limits. Enter the root
cause, corrective action information and HFI number into the NWA dat file. Refer to
administration section of the process control manual pages 4.3.1.1-5 SOP for Handling of
Critical Defects for D&I. For each occurrence of High ME a Metal Exposure Investigation
Checklist (See 1.7.1, 2, & 3) is to be completed and retained with cross reference to recorded
ME reading.

** Note: There is a process by which an individual pallet of a 5 pallet lot held due to an out of
specification reading can be released. This will require that a minimum of a 192 (two 96 can
checks) can sample be taken from each pallet considered for release. If no cans are greater
than or equal to the upper customer specification for individuals or averages for the product
being inspected, then that pallet can be released. However, the pallet that had the original
reading greater than or equal to the upper specification for individual and average must be
resprayed, reworked, or scrapped and no resample of that pallet can change that disposition.

Beverage Specification

The sampling plan for beverage uses the specifications of 25 ma for individual readings and 5
ma for the batch average.

Beer Specification

The sampling plan for beer uses the specifications 99% of readings less than 50 ma, no more
than 1% of readings greater than 50 ma but less than 75 ma, and no batch average greater
than 25 ma.

Aggressive Contents Specification

While the customer specification for Aggressive contents is the same as that for Beverage, no
product with readings greater than 10 ma for individual readings or greater than 2 ma batch
average should be released without discussions with corporate quality.



J ohn Rivard

6/7/10

3/12/09
Doug Pyer (Date)
Marlowe Wicks
(Date)

By 12/15/03
(Date)

Approved By

V.P. WCP/Quality

3
6
/1
/7
2
/
/
1
0
0
9
(Date)
7.1.14.9
3/12/09

PALLETIZER

Metal Exposure (Palletizer Pins)

Frequency of Check:

1 can from each pin / Plunger twice per shift


G-1 114 Sencon SI 9000+enamel rater gauge or Waco Sencon automatic enamel rater gauge.


Local or Corporate Data accumulation into local network.


15 MA individual / 2.0 average internal specification and 25 MA individual / 5.0 MA average for
customer specification.


Enamel Rater Solution Operating Specifications: Refer to Metal Exposure Section. Cans to be
taken off finished pallets from the side of pallet which palletizer pins and plungers come in contact
with cans.

Safety:



Refer to gauge matrix and stability chart SOP for gauge calibration frequencies.

Six Sigma:

(What Tools Used / Gauging or Process / Minimum Performance / Critical to Function) Minimum
process performance 1.0 CPU against internal specifications. Monitor by M/I/R control charts.

Training Available:

Reviewed/

Initiated By 12/8/03 Revised By 11/18/11
Doug Pyer (Date) J ohn Rivard (Date)

By 12/15/03 Approved By 11/18/11
(Date)
V.P. WCP/Quality
(Date)

3/12/09
7.2.2.2


METAL EXPOSURE

LSM IBO Exit
Internal 1
st
Pass Only, 2
nd
Pass Only, Double Spray
(CLS Enamel Electrolyte)
2-Piece DWI Steel Cans

Frequency of Check:

Q.A. Audit Production record.
Production 2 cans per LSM per pass per hour.


Selective or similar Enamel Rater Refer to Gauges Section.
CLS Enamel Electrolyte Refer to Plant Lab Test B-10.


Local


Soft Drink: 1
st
spray only: Maximum 10.0 ma
2nd spray only: Maximum 10.0 ma
1st & 2
nd
spray: Maximum 0.1 ma
Beer: 1 permitted over 1.0 ma, no cans over 10.0 ma


1. Enamel Rater test time is 45 seconds.
2. 1
st
or 2
nd
spray only No indication of iron exposure (red bleed) under 45 seconds.
Any can that shows an indication of iron exposure in less than 45 seconds is to be checked
for location of exposure and take immediate corrective action.

Safety:



Six Sigma:


Training Available:

Reviewed/


By 12/15/03 Approved By 11/18/11
(Date)
V.P. WCP/Quality
(Date)

3/12/09
7.2.2.3


METAL EXPOSURE

LSM IBO Exit
Internal 1
st
Pass Only, 2
nd
Pass Only, Double Spray
(Red Electrolyte)
2-Piece DWI Steel Cans

Frequency of Check:

Q.A. Audit Production record.
Production 12 cans per hour. (Applicable to single coat and double coat.)


Selective Enamel Rater or equivalent Refer to Gauges Section.
Red Electrolyte Refer to Plant Lab Test B-1 1.

Local


Soft Drink: 1
st
spray only: Maximum 10.0 ma
2nd spray only: Maximum 10.0 ma
1st & 2
nd
spray: Maximum 2.0 ma
Average to be: Max. 0.5 ma, permit 1 sample over 2.5 ma, and no cans read greater than 5.0 ma.

Beer: 1 permitted over 2.0 ma, no cans over 6.0 ma
Average to be: Max. 2.0 ma, no more than 1 can over 4.0 ma, no cans to be over 6.0 ma.


1. Enamel Rater test time is 4 seconds.
2. 1
st
or 2
nd
spray only Any cans over 1.0 ma must be checked for source of metal exposure.
3. 1
st
and 2
nd
spray coat Any cans over 0.5 ma must be checked for source of metal exposure.

Safety:



Six Sigma:


Training Available:

Reviewed/


By 12/15/03 Approved By 11/18/11
(Date)
V.P. WCP/Quality
(Date)

3/12/09
7.1.14.10

PALLETIZER

Decoration Adhesion Test: Beer, Soft Drink & Hot Fill

Frequency of Check:

3 cans per line, once every 4 hours



Local


Operating Specs:
Accept No loss of decoration adhesion.
Borderline Trace removal. No more than total area of 1/64 sq. in. under both strips
of tape.
Reject More than total area of 1/64 sq. in. under both strips of tape.

Safety:


Refer to plant lab test D-21.

Six Sigma:


Training Available:

Reviewed/


By 12/15/03 Approved By 11/18/11
(Date)
V.P. WCP/Quality
(Date)

3/12/09
7.1.14.11

PALLETIZER

Bottom Rim Coating Coverage

Frequency of Check:

4 cans per line every 2 hours



Local


Minimum of 100% coverage on 88% (315) around Dome bead
Pencil line not to exceed 12% (45) around Dome bead


Method of Checking Copper Sulfate Solution; Refer to Plant Laboratory Test D-7

Safety:



Six Sigma:


Training Available:

Reviewed/


By 12/15/03 Approved By 11/18/11
(Date)
V.P. WCP/Quality
(Date)

3/12/09
7.1.14.12

PALLETIZER

Dome Eversion (Buckle Test)
Note: For Plants Without Bottom Reformer Machines

Frequency of Check:

1 can per wall ironer every 2 hours


G-1 137 Altex 9009CA buckle tester gauge or other approved tester.


Local Data accumulation into local network.


90 PSI minimum.


Altek Can Buckling Tester or other approved tester. Cans to be pulled at palletizer. Data must be
recorded by wall ironer number. Buckle Tester Setting variable speed of 12.99, 10 PSI/sec. until
80 PSI, then 1.5 PSI/sec. All plants should have calibration pressure gauge and Altek gauge
should be calibrated quarterly. Refer to G-420 & G-1 116 procedures in Gauge Manual.

Safety:

Keep safety cover closed during the test.


1. Refer to G-420 and G-1116 procedures in Gauge Manual.
2. Refer to gauge matrix and stability chart SOP for gauge calibration frequencies.

Six Sigma:

(What Tools Used / Gauging or Process / Minimum Performance / Critical to Function) Monitor by
M/I/R control charts. Minimum process performance 1.0 Cpl for internal specifications.

Training Available:

Reviewed/


By 12/15/03 Approved By 11/18/11
(Date)
V.P. WCP/Quality
(Date)

3/12/09
7.1.14.13

PALLETIZER

Dome Eversion
Note: For Plants With Bottom Reformer Machines

Frequency of Check:

1 can per reformer station every 2 hours


G-1137 Altek 9009CA buckle tester gauge or other approved tester.


90 PSI minimum


Altek Can Buckling Tester or other approved tester. Cans to be pulled at palletizer. Data must be
recorded by wall ironer number. Buckle Tester Setting speed of 10 PSI/sec. until 80 PSI, then
1.5 PSI/sec. All plants should have calibration pressure gauge and Altek gauge should be
calibrated quarterly. Refer to G-420 & G-1116 procedures in Gauge Manual.

Safety:

Keep safety cover closed during the test.


Six Sigma:
(What Tools Used / Gauging or Process / Minimum Performance / Critical to Function) Monitor by
M/I/R control charts. Minimum process performance 1.0 Cpl for internal specifications.

Training Available:

Reviewed/


By 12/15/03 Approved By 11/18/11
(Date)
V.P. WCP/Quality
(Date)

3/12/09
7.1.14.14

PALLETIZER

Bottom Bead Diameter
Note: For Plants With Bottom Reformer Machines

Frequency of Check:

1 can per reformer station per shift



Local



Mitutoyo Dial Caliper Internal Type #209-113 2.2 range, .001 graduation. Specification for Bottom
Bead Diameter from ESM Sheets +/- .005.

Safety:



Six Sigma:


Training Available:

Reviewed/


By 12/15/03 Approved By 11/18/11
(Date)
V.P. WCP/Quality
(Date)

3/12/09
7.1.14.15

PALLETIZER

Axial Load

Frequency of Check:

2 finished cans per wall ironer twice per shift


G-1 133 Altek axial load tester Model 9221 C.




Minimum 180 lb beer and 175 lb soft drink.
Can samples must be dent free. Pull cans at palletizer. Pull can samples from each palletizer belt
on all running lines / bodymakers.

Safety:




Six Sigma:

process performance 1.0 CPL against internal specifications. Monitor by M/I/R control charts.

Training Available:

Reviewed/


By 12/15/03 Approved By 11/18/11
(Date)
V.P. WCP/Quality
(Date)

3/12/09
7.1.14.16

12/8/03
Doug Pyer (Date)

12/15/03
(Date)

PLANT AIR SUPPLY

Verify Plant Air is Free of Oil

Frequency of Check:

Once per month


Camphor Test as explained in the SOP Section (Click Here to Link to SOP Pages)
Local Data accumulation into local network


No evidence of oil in the air is permitted


Sample the air at a point in the line where all process air will be tested. If oil is present At this
point, then more testing must be done to isolate the compressor at fault, if there is more than one
air compressor in the system.

Safety:


Six Sigma:

process performance 1.0 CPL against internal specifications. Monitor by M/I/R control charts.

Training Available:

The SOP should give guidance needed for the test. If there are any questions, please notify the
Quality Department.

Initiated By
10/5/06
Reviewed/

Revised By 11/18/11
Marlowe Wicks
(Date) J ohn Rivard (Date)

By
10/5/06
Approved By 11/18/11
Sr. Mgr. WCP/Quality
(Date)
V.P. WCP/Quality
(Date)

Can Inspection Process Documentation

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