Washing Soiled Garments
LESSON 4 CONDUCTING QUALITY CONTROL TESTS After completing this lesson, you will be able to accurately test the level of particles and fibers left in a washed and dried garment.
Why These Skills Are Important By conducting federally mandated tests regularly, the cleaned gar meet the necessary cleanroom standards.
ments
Key Terms ASTM F51: A Standard Test Method (ASTM) that collects particles and fibers on a gridded membrane filter from five sample areas in and on clean room garments. The ASTM F51 particle counter is comprised of the following parts:
Hose
Top Portion Filter Assembly
Fiber: Microscopic contaminants that are in the air and on garments. Under a microscope these look like a hair or eyelash.
Rev. May 2012
2012 MSR-FSR. All rights reserved.
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Conducting Quality Control Tests
Helmke Drum Test: This quality control test simulates particle shedding of clothing under movement. A garment is tumbled in a rotating drum to release particles from the surface of the cleanroom garment. An automatic particle counter is used to sample the air within the drum to determine the average particle concentration of the air during the initial ten minutes of the test.
Particle: Microscopic contaminants that are in the air and on garments. Under a microscope these look like black specks. Lighthouse Software Program: A particle monitoring system that records the results to the Helmke tests.
Before You Begin To ensure a consistent level of cleanliness, a garment must be tested at least once a day. This test is most commonly conducted on a large coverall. The two methods of testing for a quality control are the Helmke Drum Test and the ASTM F51 Test. These tests should be conducted on one washed and dried garment per shift. IMPORTANT: Always conduct testing in the cleanroom area while wearing Class 10 cleanroom garments. Failure to do so may negatively influence test results. The particles counts must be at or below the federally mandated guidelines: Gore: 300 Poly: 1,000 If the particle count is higher than these recommendations, the tests must be conducted on two additional garments. If these additional garments do not pass the tests, the entire load must be washed and tested again. Rev. May 2012
2012 MSR-FSR. All rights reserved.
Conducting Quality Control Tests
35
Here’s How To test garments using both the Helmke Drum Test and the ASTM F1 Test: Take workers into the cleanroom and demonstrate the following tasks: Testing a garment using the Helmke drum Testing a garment using the ASTM F51 process
As you supervisor demonstrates these procedures, follow along with the steps below:
Helmke Drum Test The Helmke Drum Test is most often conducted on both gore and polyester garments. To conduct the Helmke Drum Test: 1. Check to be sure the hose is connected to the wall mounted particle counter. 2. Open the door to the drum. Be sure the white sampling hose is tucked into the silver tube at the back of the drum.
Explain that to prevent contamination, new latex gloves must be put on before touching the testing garment.
The particle counter should be set to Ready to Count. 3. 4. 5. 6.
Remove the outer pair of latex gloves. Put on a new pair of latex gloves. From the dryer, select a large coverall for testing. Gather the coverall into a loose ball. IMPORTANT: Do not shake the garment or let it touch your body, the floor, or any other surfaces.
7. Place the garment into the Helmke drum. 8. Close and latch the door. 9. Flip the switch to On. The drum begins the tumble the garment and count particles. 10. Wait 10 minutes. Tell workers to monitor the time closely as the Helmke drum does not have a timer or an auto shut off feature.
IMPORTANT: The measurements must be taken within the first 10 minutes of tumbling. Failure to conduct the test in that time frame invalidates the test. The particle concentration count is recorded on the Lighthouse software program. 11. Note the results on the Helmke results table. The Helmke Drum Test is complete.
Rev. May 2012
2012 MSR-FSR. All rights reserved.
36
Conducting Quality Control Tests
ASTM F51 Test The ASTM F51 Test is most often polyester fibers. To conduct the ASTM F51 Test: 1. Remove the plastic covering from microscope and hoses. 2. Turn on the microscope. 3. Connect the clear hose to the particle counter mounted on the wall.
Explain that counting particles and fibers on a clean filter these contaminants will not be included in the overall particle and fiber count.
4. Using a set of tweezers, place a clean gridded filter on a glass slide. IMPORTANT! Do not let the filter touch anything to prevent contamination.
5. 6. 7. 8. 9.
Place the slide under the microscope. Count the number of particles and fibers on the clean filter. Remove the outer pair of latex gloves. Put on a new pair of latex gloves. From the dryer, select a pair of large coveralls for testing. IMPORTANT! Do not shake the garment or let it touch your body, the floor, or any other surfaces.
10. Lay the garment on the flat testing surface.
Rev. May 2012
2012 MSR-FSR. All rights reserved.
Conducting Quality Control Tests
37
11. Using tweezers, transfer the filter from the microscope to the end of the hose attachment.
12. Screw on the filter cover. 13. Place a single layer of the garment over the filter. 14. Place the top filter over the garment as shown in the image below: Hose
Filter Assembly
Top Filter
Garment
Suggest that workers conduct the test on each arm and leg and on the back of the garment.
Rev. May 2012
15. 16. 17. 18. 19. 20. 21.
Hold in place for 1 minute. Repeat in a total of 5 places on the garment. Remove the top filter and garment. Unscrew the filter cover. Using tweezers, remove the filter from the hose. Place the filter on a glass slide. Place the slide under the microscope.
2012 MSR-FSR. All rights reserved.
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Conducting Quality Control Tests
22. Count the number of particles in each quadrant of the filter as shown in the figure below:
23. Subtract this number from the control number. Example: The initial count revealed a total of 1 fiber and 10 particles. The test count revealed 4 fibers and 30 particles. The total number of fibers is then 3 (4-1=3). The total number of particles is20 (30-10=20). Explain that because the worker counts 10 squares in each quadrant, this number is 40.
24. Multiply the total number of particles by the total number of squares. Example: Based on the example above, the total number of particles is 20. 20 x 20 = 400 Do not include fibers or the control sample in the equation. 25. Record the results on the Test Results Table. Refer to the Accessing Information in the Lighthouse Program section of this manual. 26. 27. 28. 29.
Rev. May 2012
Dispose of filters. Reconnect the hose to the Helmke drum. Cover the microscope with plastic. Return tested garment to folding area.
2012 MSR-FSR. All rights reserved.
Conducting Quality Control Tests
39
Accessing Information in Lighthouse Program 1. In the left hand window pane, click Create New Data Table. 2. In the Data Table Name field, type in the current date.
Enter Current Date
3. Click Data Tab.
4. Click Add.
Rev. May 2012
2012 MSR-FSR. All rights reserved.
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Conducting Quality Control Tests
5. Select Data Type.
6. From the Instrument drop down list, select Helmke. 7. Double click .3 counts and .5 counts.
8. Click OK.
Rev. May 2012
2012 MSR-FSR. All rights reserved.
Conducting Quality Control Tests
41
9. Click the Time Range tab.
10. 11. 12. 13. 14.
Rev. May 2012
Click Fixed Range. Change start time to when the garment was first placed in the Helmke drum. Change the end time to 10 minutes later. Click OK. Record the number listed in the Average field on the notebook located in the testing area.
2012 MSR-FSR. All rights reserved.
42
Conducting Quality Control Tests
Exercise In this exercise, you will test and log cleaned garments. If you have any questions, ask your supervisor for assistance. Scenario While working in the folding room, you are asked to demonstrate your knowledge of the two testing processes. Shadow the new worker as the listed tasks are performed. Provide positive feedback and recommendations for improvement. Do NOT leave the worker during this time. Make sure that proper procedures are being followed.
Directions Answer the following questions about garment testing. 1. How often should a test be conducted? A. B. C. D.
Once every washload Once every shift Once every day All the above
2. If a garment does not pass the test process, what should be done?
3. What software program calculates the Helmke test results? A. B. C. D.
Excel GIMS Lighthouse None, it is calculated manually
4. ______ T/F The garment must tumble in the Helmke drum more than 10 minutes before the results can be recorded.
5. How many points on a garment should be tested when using the ASTM F51 test? A. B. C. D.
1 3 5 7
How Did You Do? Discuss the exercise with the supervisor. If you have any questions, ask your supervisor for clarification or assistance. Rev. May 2012
2012 MSR-FSR. All rights reserved.
Conducting Quality Control Tests
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Answers 1. B 2. If the particle count is higher than recommended, the tests must be conducted on two additional garments. If these additional garments do not pass the tests, the entire load must be washed and tested again. 3. C 4. False. The test should be conducted on the garment within the first 10 minutes of tumbling. 5. C
Rev. May 2012
2012 MSR-FSR. All rights reserved.
Why These Skills Are Important By conducting federally mandated tests regularly, the cleaned gar meet the necessary cleanroom standards.
ments
Key Terms ASTM F51: A Standard Test Method (ASTM) that collects particles and fibers on a gridded membrane filter from five sample areas in and on clean room garments. The ASTM F51 particle counter is comprised of the following parts:
Hose
Top Portion Filter Assembly
Fiber: Microscopic contaminants that are in the air and on garments. Under a microscope these look like a hair or eyelash.
Rev. May 2012
2012 MSR-FSR. All rights reserved.
34
Conducting Quality Control Tests
Helmke Drum Test: This quality control test simulates particle shedding of clothing under movement. A garment is tumbled in a rotating drum to release particles from the surface of the cleanroom garment. An automatic particle counter is used to sample the air within the drum to determine the average particle concentration of the air during the initial ten minutes of the test.
Particle: Microscopic contaminants that are in the air and on garments. Under a microscope these look like black specks. Lighthouse Software Program: A particle monitoring system that records the results to the Helmke tests.
Before You Begin To ensure a consistent level of cleanliness, a garment must be tested at least once a day. This test is most commonly conducted on a large coverall. The two methods of testing for a quality control are the Helmke Drum Test and the ASTM F51 Test. These tests should be conducted on one washed and dried garment per shift. IMPORTANT: Always conduct testing in the cleanroom area while wearing Class 10 cleanroom garments. Failure to do so may negatively influence test results. The particles counts must be at or below the federally mandated guidelines: Gore: 300 Poly: 1,000 If the particle count is higher than these recommendations, the tests must be conducted on two additional garments. If these additional garments do not pass the tests, the entire load must be washed and tested again. Rev. May 2012
2012 MSR-FSR. All rights reserved.
Conducting Quality Control Tests
35
Here’s How To test garments using both the Helmke Drum Test and the ASTM F1 Test: Take workers into the cleanroom and demonstrate the following tasks: Testing a garment using the Helmke drum Testing a garment using the ASTM F51 process
As you supervisor demonstrates these procedures, follow along with the steps below:
Helmke Drum Test The Helmke Drum Test is most often conducted on both gore and polyester garments. To conduct the Helmke Drum Test: 1. Check to be sure the hose is connected to the wall mounted particle counter. 2. Open the door to the drum. Be sure the white sampling hose is tucked into the silver tube at the back of the drum.
Explain that to prevent contamination, new latex gloves must be put on before touching the testing garment.
The particle counter should be set to Ready to Count. 3. 4. 5. 6.
Remove the outer pair of latex gloves. Put on a new pair of latex gloves. From the dryer, select a large coverall for testing. Gather the coverall into a loose ball. IMPORTANT: Do not shake the garment or let it touch your body, the floor, or any other surfaces.
7. Place the garment into the Helmke drum. 8. Close and latch the door. 9. Flip the switch to On. The drum begins the tumble the garment and count particles. 10. Wait 10 minutes. Tell workers to monitor the time closely as the Helmke drum does not have a timer or an auto shut off feature.
IMPORTANT: The measurements must be taken within the first 10 minutes of tumbling. Failure to conduct the test in that time frame invalidates the test. The particle concentration count is recorded on the Lighthouse software program. 11. Note the results on the Helmke results table. The Helmke Drum Test is complete.
Rev. May 2012
2012 MSR-FSR. All rights reserved.
36
Conducting Quality Control Tests
ASTM F51 Test The ASTM F51 Test is most often polyester fibers. To conduct the ASTM F51 Test: 1. Remove the plastic covering from microscope and hoses. 2. Turn on the microscope. 3. Connect the clear hose to the particle counter mounted on the wall.
Explain that counting particles and fibers on a clean filter these contaminants will not be included in the overall particle and fiber count.
4. Using a set of tweezers, place a clean gridded filter on a glass slide. IMPORTANT! Do not let the filter touch anything to prevent contamination.
5. 6. 7. 8. 9.
Place the slide under the microscope. Count the number of particles and fibers on the clean filter. Remove the outer pair of latex gloves. Put on a new pair of latex gloves. From the dryer, select a pair of large coveralls for testing. IMPORTANT! Do not shake the garment or let it touch your body, the floor, or any other surfaces.
10. Lay the garment on the flat testing surface.
Rev. May 2012
2012 MSR-FSR. All rights reserved.
Conducting Quality Control Tests
37
11. Using tweezers, transfer the filter from the microscope to the end of the hose attachment.
12. Screw on the filter cover. 13. Place a single layer of the garment over the filter. 14. Place the top filter over the garment as shown in the image below: Hose
Filter Assembly
Top Filter
Garment
Suggest that workers conduct the test on each arm and leg and on the back of the garment.
Rev. May 2012
15. 16. 17. 18. 19. 20. 21.
Hold in place for 1 minute. Repeat in a total of 5 places on the garment. Remove the top filter and garment. Unscrew the filter cover. Using tweezers, remove the filter from the hose. Place the filter on a glass slide. Place the slide under the microscope.
2012 MSR-FSR. All rights reserved.
38
Conducting Quality Control Tests
22. Count the number of particles in each quadrant of the filter as shown in the figure below:
23. Subtract this number from the control number. Example: The initial count revealed a total of 1 fiber and 10 particles. The test count revealed 4 fibers and 30 particles. The total number of fibers is then 3 (4-1=3). The total number of particles is20 (30-10=20). Explain that because the worker counts 10 squares in each quadrant, this number is 40.
24. Multiply the total number of particles by the total number of squares. Example: Based on the example above, the total number of particles is 20. 20 x 20 = 400 Do not include fibers or the control sample in the equation. 25. Record the results on the Test Results Table. Refer to the Accessing Information in the Lighthouse Program section of this manual. 26. 27. 28. 29.
Rev. May 2012
Dispose of filters. Reconnect the hose to the Helmke drum. Cover the microscope with plastic. Return tested garment to folding area.
2012 MSR-FSR. All rights reserved.
Conducting Quality Control Tests
39
Accessing Information in Lighthouse Program 1. In the left hand window pane, click Create New Data Table. 2. In the Data Table Name field, type in the current date.
Enter Current Date
3. Click Data Tab.
4. Click Add.
Rev. May 2012
2012 MSR-FSR. All rights reserved.
40
Conducting Quality Control Tests
5. Select Data Type.
6. From the Instrument drop down list, select Helmke. 7. Double click .3 counts and .5 counts.
8. Click OK.
Rev. May 2012
2012 MSR-FSR. All rights reserved.
Conducting Quality Control Tests
41
9. Click the Time Range tab.
10. 11. 12. 13. 14.
Rev. May 2012
Click Fixed Range. Change start time to when the garment was first placed in the Helmke drum. Change the end time to 10 minutes later. Click OK. Record the number listed in the Average field on the notebook located in the testing area.
2012 MSR-FSR. All rights reserved.
42
Conducting Quality Control Tests
Exercise In this exercise, you will test and log cleaned garments. If you have any questions, ask your supervisor for assistance. Scenario While working in the folding room, you are asked to demonstrate your knowledge of the two testing processes. Shadow the new worker as the listed tasks are performed. Provide positive feedback and recommendations for improvement. Do NOT leave the worker during this time. Make sure that proper procedures are being followed.
Directions Answer the following questions about garment testing. 1. How often should a test be conducted? A. B. C. D.
Once every washload Once every shift Once every day All the above
2. If a garment does not pass the test process, what should be done?
3. What software program calculates the Helmke test results? A. B. C. D.
Excel GIMS Lighthouse None, it is calculated manually
4. ______ T/F The garment must tumble in the Helmke drum more than 10 minutes before the results can be recorded.
5. How many points on a garment should be tested when using the ASTM F51 test? A. B. C. D.
1 3 5 7
How Did You Do? Discuss the exercise with the supervisor. If you have any questions, ask your supervisor for clarification or assistance. Rev. May 2012
2012 MSR-FSR. All rights reserved.
Conducting Quality Control Tests
43
Answers 1. B 2. If the particle count is higher than recommended, the tests must be conducted on two additional garments. If these additional garments do not pass the tests, the entire load must be washed and tested again. 3. C 4. False. The test should be conducted on the garment within the first 10 minutes of tumbling. 5. C
Rev. May 2012
2012 MSR-FSR. All rights reserved.
