How to Prevent Sharp Objects from Remaining in Plush Toys during Production and Packaging

In the production and packaging of plush toys, ensuring that no broken needles, scissors, or other sharp objects are left inside is crucial for consumer safety. Here are some effective measures to prevent such incidents.

I. Production Phase

1. Needle Management

- Use high - quality needles that are less likely to break. Regularly inspect needles for signs of wear or damage before and during use. Replace needles at the first sign of dullness or bending.

- Implement a strict needle - counting system. Keep a record of the number of needles issued to each worker at the beginning of a shift. When a needle breaks, all parts of the broken needle must be accounted for immediately. Workers should stop production and search thoroughly for any missing pieces. If a part cannot be found, the semi - finished product in process should be set aside for further inspection.

2. Tool Control

- Provide workers with designated storage containers for scissors and other sharp tools. These tools should be stored in these containers when not in use, reducing the chance of them being misplaced in the production area.

- Conduct regular tool checks during production. Workers should be required to report any missing tools immediately. A supervisor should then lead a search effort to locate the tool.

II. Packaging Phase

1. Final Inspection

- Establish a comprehensive final inspection process before packaging. Trained inspectors should visually examine each plush toy, checking for any signs of damage that could indicate a sharp object is inside. They should also feel the toy carefully for any hard or sharp protrusions.

- Use metal detectors in the packaging line. This is an essential step to identify any metal - containing sharp objects such as broken needles that may have gone unnoticed during the visual and manual inspection. All plush toys must pass through the metal detector before being packaged. If the metal detector alarms, the toy should be removed for further inspection, and the source of the detected metal should be identified and resolved.

2. Packaging Environment Management

- Keep the packaging area clean and organized. Remove any unnecessary sharp objects from the packaging workspace. Regularly clean the worktables and floors to prevent sharp items from being accidentally swept into the packaging area.

- Train packaging workers on the importance of preventing sharp objects from entering the packages. They should be vigilant and report any suspicious items or situations immediately.

By implementing these strict procedures in both the production and packaging phases, manufacturers can significantly reduce the risk of sharp objects being left inside plush toys, thus ensuring the safety of consumers, especially children who are the main users of these products.