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Simulated workplace
Scenario · Food and Beverage Production

Manage a metal detector test failure

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

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The situation

What has happened

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.

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.
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Tasks

Deliverables

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

Documents to use

Systems to use

Critical Control Point Monitoring Log

Shift by shift monitoring records for every critical control point, with readings, limits, results and verification.

Production Batch Records

Every food, beverage and pharmaceutical batch from planning to release, with line, quantity, status and the notes that support release.

Non-conformance and CAPA Register

Register of every non-conformance, deviation, complaint and safety incident with investigation, corrective and preventive action and closure status.

For trainers and assessors

Units of competency

Current on training.gov.au for the Food, Beverage and Pharmaceutical as at 10 September 2026.

FBPFSY1002Follow work procedures to maintain food safety
FBPOPR1014Monitor process operation
FBPOPR1016Take and record basic measurements
FBPOPR2068Operate a process control interface
FBPWHS2001Participate in work health and safety processes

Qualifications

FBP20122Certificate II in Food Processing
FBP10121Certificate I in Food Processing
Assessor notes

What to look for

Evidence guide

The student must show the hold scope was checked against the log rather than assumed, the full test was done and recorded before re-passing, every pack was accounted for, and records were made at the time. The non-conformance report must contain facts and quantities, not opinions about blame, and the handover note must state the batch status clearly.

The student's evidence summary lists every record they created or changed in the systems named above, their notes and the tasks they ticked. Verify it against the deliverables and your own assessment tool.