Foreign Material Control Program Audit

Inspection template for auditing foreign material controls against the site foreign material plan, including magnets, screens, knives, brittle-item controls, and physical contamination prevention practices.

Audit Scope and Foreign Material Plan Review

• Current foreign material control plan is available and matches the audited area
  Verify the plan is site-specific, current, and covers the process area being inspected.
• Hazard points and control devices are identified in the plan
  Confirm the plan identifies magnets, screens, knives, brittle items, and other physical contamination control points.
• Recent changes to equipment, product, or layout have been assessed for foreign material risk
  Check whether process changes, maintenance work, or layout changes triggered a plan review.
• Inspection frequency and responsibilities are defined and followed
  Verify the plan assigns ownership and inspection intervals for control verification.

Magnets and Metal Separation Controls

• Magnets are installed at specified control points
  Confirm magnets are present where required by the foreign material plan and positioned to intercept product flow.
• Magnet housings, guards, and access points are intact and secure
  Inspect for damage, loose fasteners, missing covers, or conditions that could reduce effectiveness.
• Magnet strength verification is current
  Confirm documented verification or pull-test results are within the required interval and meet site criteria.
• Magnet cleaning and release records are complete
  Review records showing magnets are cleaned, inspected, and cleared at the required frequency.

Screens, Sieves, and Physical Barriers

• Screens and sieves are installed, intact, and properly seated
  Verify screens are present where required and show no tears, gaps, deformation, or bypass conditions.
• Screen mesh or opening size matches the approved specification
  Confirm the installed screen matches the foreign material plan or equipment specification.
• Screen inspection and replacement records are current
  Verify documented checks are completed on schedule and damaged screens are replaced promptly.
• Bypass or temporary removal of screens is controlled and documented
  Check that any bypass condition is authorized, time-limited, and covered by corrective action or risk assessment.

Knives, Blades, and Cutting Tool Control

• Knives and blades are controlled by issue, count, or sign-out process
  Verify tools are tracked to prevent loss, breakage, or unaccounted-for fragments.
• Blades are intact and free of chips, cracks, or missing segments
  Inspect in-use cutting tools for damage that could create foreign material.
• Blade change and disposal process is followed
  Confirm used blades are removed into a controlled sharps or blade disposal container and not left in the area.

Brittle Item and Glass Control

• Brittle items are identified on the brittle-item register
  Verify glass, hard plastic, ceramic, and similar items are listed and controlled per the site program.
• Brittle item inspections are current and documented
  Confirm scheduled inspections are completed and any damaged items are removed from service.
• Glass and brittle-item breakage response procedure is posted and understood
  Check that employees know the response steps for breakage, cleanup, product hold, and release authorization.
• Protective covers, shields, or exclusion controls are intact where required
  Inspect light covers, gauges, lenses, and other brittle components for protection and integrity.

Housekeeping, Inspection Records, and Corrective Actions

• Area is free of loose foreign material sources
  Check for loose fasteners, broken plastic, wire, tape, wood, or other contamination sources in the audited area.
• Foreign material inspection logs are complete and legible
  Review logs for required checks, signatures, dates, and any noted deficiencies or non-conformances.
• Open deficiencies have documented corrective actions and due dates
  Verify corrective actions are assigned, tracked, and closed within the required timeframe.
• Employees can explain escalation for a suspected foreign material event
  Confirm personnel know when to stop the line, segregate product, notify supervision, and initiate investigation.