3020H

 QUALITY AND SAFETY OPERATING PROCEDURE 1. SCOPE 1.1. TITLE SHARP POINTS NUMBER REVISION DATE 0006-3020 AUTHOR H REVISED BY 09/13/06 D. Taylor Q. Lim Products and Components Covered 1.1.1. All products intended for children less than 14 years. 1.1.2. As-received packaging including all plastic and tie wraps etc. 1.2. Exemptions 1.2.1. Functional sharp points on toys suitable for children over 48 months of age. Reference QSOP 0006-3549, Labeling of Products with Functional Sharp Points/Edges. 1.2.2. Sharp points on toys intended to be assembled by an adult, if the points are accessible when unassembled only. Reference QSOP 0006-3556, Labeling of Products Intended to be Assembled by an Adult 1.2.3. Sharp points on sprues after the parts have been removed. 1.3. Definitions (Words defined are italicized and bolded once per section). Accessible: Any area of the toy that can be contacted by any portion forward of the collar of the accessibility probes when inserted to the depth determined in QSOP 0006-3010, Accessibility. Discharge Mechanism: A device intended to discharge and propel an object. Functional Sharp Point: an accessible point that is necessary for the function of the toy and lights the gage when tested per §3.4 QSOP 0006-3020 H PI CONFIDENTIAL - MATTEL, INC. PROPRIETARY INFORMATION Page 1 of 6 Hazardous Sharp Point: A sharp point that presents an unreasonable risk of injury. Points on toys are considered as potentially hazardous sharp points if they light the sharp point tester. If they light the sharp point tester, they shall then be assessed to determine if they present an unreasonable risk of injury taking into account the following to determine if it is hazardous: • A toy's play pattern or reasonably foreseeable misuse. • The level of adult supervision likely with such a toy. • The age of the child for which the toy is intended. • Whether the toy presents a sharp point hazard while it is still functional. • The accessibility of the potentially hazardous sharp point. • Whether the potentially hazardous sharp point is present before or after use and abuse testing. • Whether the potentially hazardous sharp points is on a piece that broke off from the toy after abuse testing and whether such piece will likely be kept or discarded. • Configuration of the point (e.g. the relative degree of bluntness or sharpness, cross-sectional thickness, point stiffness). Documentation must be kept to support all such determinations. Projectile: An object intended to be propelled into the air by any means, including objects restrained at the end of a string, elastic or other form of attachment, such as a pop gun. 2. PERFORMANCE REQUIREMENTS 2.1. All Ages 2.1.1. Regardless of age grading, a product must have no accessible, hazardous sharp points. 2.1.2. Regardless of age grading, as received packaging must have no accessible, hazardous sharp points. 2.1.3. The accessible surfaces and edges of wood must be free of splinters. 2.1.4. Projectiles that are thrown or propelled by a discharge mechanism are considered hazardous if they light the sharp point tester. 2.2. Products Suitable for Children 3 Years and Under 2.2.1. Metal points and wires with the major dimension of the cross section of 2 mm or less are considered to be potentially hazardous sharp points without further testing. They must not be a hazardous sharp point. QSOP 0006-3020 H PI CONFIDENTIAL - MATTEL, INC. PROPRIETARY INFORMATION Page 2 of 6 3. TEST METHODS 3.1. Test Environment (not applicable) 3.2. Equipment 3.2.1. Sharp point tester1: (see Figure 1). 3.2.2. Metal Collar: added to the tester barrel. The collar should to bring the total tester weight to 1 lb. (0.45 kilograms). Gap is closed when sufficiently sharp point passes through gaging slot & depresses sensing head 0.005\". Electric circuit is then completed & indicator test lamp lights indicating a potential hazardous sharp point. FIGURE 1: Sharp Point Tester 1 Manufactured by U.S. Testing Co. Inc., Model #A210. PI CONFIDENTIAL - MATTEL, INC. PROPRIETARY INFORMATION Page 3 of 6 QSOP 0006-3020 H 3.2.3. Loading device: Sharp Edge Tester handle2, (Figure 2). 3.2.3.1. Attach the adaptor to the sharp edge tester handle arm (Figure 2). 3.2.3.2. Assemble the sharp point tester to the adaptor. 3.2.3.3. Adjust the loading device arm length so 1 lb. (4.4 N) applied to the gage cap face is required to move the arm away from \"normal\" and into \"calibration\". (Ensure that the arm does not travel past the calibration position to contact the stop.) 3.2.4. Loading device: Metal Collar. Add a metal collar to the tester barrel to ensure the full weight of the unit is 1.0 lb (4.4 N) is applied. FIGURE 2: Sharp Edge Tester Handle 3.3. General Test requirements 3.3.1. Determine if the suspect point is accessible per QSOP 0006-3010, Accessibility. 3.3.2. Part of the test sample may need to be removed to allow the sharp point tester to test an accessible point. If such dismantling of the toy affects the sample’s rigidity, support the point so its rigidity approximates, but is not greater than, the point stiffness in the assembled unit. Provide support at not less than 0.25 inch (6 mm) from the point to be tested 2 Manufactured by Technical Engineering Service, Model # SET-50. PI CONFIDENTIAL - MATTEL, INC. PROPRIETARY INFORMATION Page 4 of 6 QSOP 0006-3020 H 3.4. Procedure 3.4.1. Sharp Point Tester with Sharp Edge Tester Handle: 3.4.1.1. Calibrate the tester by; • • • Loosen the lock ring on the sharp point tester. Rotate the gage cap clockwise until the indicator lamp just lights. Rotate the cap counterclockwise until five divisions (the distance between the short lines on the cap) have passed the calibration reference mark. Lock the gage cap in this position by rotating the lock ring until it fits firmly against the cap. • 3.4.1.2. Apply a 1-lb. (4.4 N) force to the point by rotating the loading device handle until the arm and handle centerlines are aligned in the \"calibration\" position. 3.4.1.3. A glowing light indicates a potentially hazardous sharp point. 3.4.2. Sharp Point Tester with Metal Collar: 3.4.2.1. Calibrate the tester by per §3.4.1.1 3.4.2.2. Hold the sharp point tester with its axis vertical and the gaging slot facing downwards. Balance the tester on the tip of the suspected sharp point. 3.4.2.3. A glowing light indicates a potentially hazardous sharp point. 4. HISTORY 4.1. Significance To minimize potential puncture and laceration hazards associated with sharp points on toys. 4.2. Reason for Revisions Section Revision G Implementation Date: §2.1 Metal points and wires with cross section of 2mm or less Immediately are considered potentially hazardous sharp points per EN71-1:2005. QSOP 0006-3020 H PI CONFIDENTIAL - MATTEL, INC. PROPRIETARY INFORMATION Page 5 of 6 Section Revision H Implementation Date: §2.2 Modified requirement - Suitable for children 3 years and Immediately under - Metal points and wires with the major dimension of the cross section of 2 mm or less are considered to be potentially hazardous sharp points . 4.3. Referenced Documents 16 CFR 1500. ASTM F963-96a EN71, Part 1:2005 ISO 8124-1: 2000 Canadian Hazardous Products Act Japan Toy Safety Standard 2002 Chinese National Toy Safety Standard 4797-1979 Brazilian Toy Safety Standard NBR 11786–1998 Singapore Specification for Safety of Toys Part 1- 2000 Taiwan TIS 685 Part 2 –2540 Amendment No. 1, 1997 Saudi Standard No. 1063/1995 Part 1 Indian Standard Safety Requirements for Toys Part 1- 1981 Korean Safety Inspection Regulation for Toy Part 1 - 2001 QSOP 0006-3020 H PI CONFIDENTIAL - MATTEL, INC. PROPRIETARY INFORMATION Page 6 of 6