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presented by David Burns

AWARENESS TRAINING PROGRAMME Technical Standard and Protocol for Companies Supplying Retailer Branded Food Products. presented by David Burns. Retailers Safeway Tesco Asda Sainsbury Iceland Somerfield CWS Boots Waitrose. Who Were Involved ?. Inspection Bodies EFSIS TLC Law Labs

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presented by David Burns

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  1. AWARENESS TRAINING PROGRAMMETechnical Standard and Protocol for Companies Supplying Retailer Branded Food Products presented by David Burns

  2. Retailers Safeway Tesco Asda Sainsbury Iceland Somerfield CWS Boots Waitrose Who Were Involved ? • Inspection • Bodies • EFSIS • TLC • Law Labs • RSSL • National Britannia • Trade • Associations • FDF • BACFID Accreditation Body • UKAS

  3. FOUNDATION LEVEL Consistency of Inspection HIGHER LEVEL Additional Beneficial Practices BEST PRACTICE RECOMMENDATIONS UKAS & EN 45004 NEW EN 45011

  4. Benefits of the Standard • Accepted Standard based on best practice • Inspection bodies accredited to EN45004 to achieve maximum consistency in application and interpretation (this is changing to EN 45011, refer to Protocol section) • Open and transparent • Encourages continuous improvement • Cost effective, removes need for multiple inspections

  5. UKAS Accreditation (Mark)

  6. Benefits for the Retailer • Removes “burden” of “routine” visits • Focus on HACCP development • Focus on quality • Focus on complaint issues • Focus on “hot” issues e.g GMO,allergen

  7. Benefits for the Manufacturer • Resource benefit as due diligence visits are reduced • Focus on factory issues • Focus on development • Focus on specific Retailer requirements • Cost effective, independent and professional audit

  8. CERTIFICATION • Accredited Certification (UKAS): • Quality Management • Product Certification

  9. TYPES OF STANDARDS • Food Standards in Europe • Voluntary Codes • EU Legislated

  10. TYPES OF STANDARDS • Voluntary Codes (for example) • Animal Feeds • Cereals • Horticultural Produce • Dairy Produce • Beef, Lamb, Pork

  11. TYPES OF STANDARDS • EU Legislated (for example) • Food Labelling • Beef Labelling • Organic Food Production • Egg Production • Animal Welfare • Environment

  12. HACCP Majority of Food Chain Standards incorporate Hazard Analysis Critical Control Point(HACCP)

  13. BRC - STANDARD CONTENTS • 1. HACCP System • 2. Quality Management System • 3. Factory Environment Standards • 4. Product Control • 5. Process Control • 6. Personnel

  14. BRC - TECHNICAL STANDARD • The BRC Standard is divided into two levels, as follows: • Foundation Level • Higher Level

  15. BRC & HACCP Useful reference documentation as suggested by the BRC Working Group Title: Hazard Analysis Critical Control Points (HACCP) system Guidelines for its Application Published in: Codex Alimentarius Food Hygiene Texts Ref. Number: ISBN 92-5-104021-4

  16. THE STANDARD REQUIREMENTS • 1. HACCP • HACCP - Principles • Conduct hazard analysis • Determine critical control points • Establish critical limits programme • Monitor against programme • Establish corrective action • Verification and validation records • Establish documentation

  17. THE STANDARD REQUIREMENTS • HACCP - Risk • Assessment of the identified risk • Reference to appropriate technical documentation • Prioritisation of monitoring programme • Monitor recurring trends • Underpinned by technical personnel

  18. THE STANDARD REQUIREMENTS • HACCP - Management • HACCP led by Senior Management commitment • Reference to product legal and safety obligations • Technically competent HACCP team • Plotting the CCP through the production process • Identification with reference to technical working instructions / methods for CCP • Proof of training / awareness for HACCP at all appropriate levels

  19. THE STANDARD REQUIREMENTS • 2. QUALITY MANAGEMENT SYSTEM • 2.1 Quality Management System (QMS) General Requirements • Identify the processes needed for the QMS application • Sequence and interaction of processes • Determine criteria and methods to ensure operational control(s) • Resources management • Monitor, measurement and analysis • Implementation, planning and improvement

  20. THE STANDARD REQUIREMENTS • 2. QUALITY MANAGEMENT SYSTEM • 2.2 Quality Policy Statement • Published statement by the Top Management • Commitment to the Standard requirements • Appropriate to the purpose of the company • Commitment to continuous improvement • Establishing and reviewing quality objectives • Communicated and understood • Reviewed for continuing suitability • Authorised and approved by Top Management

  21. THE STANDARD REQUIREMENTS • 2.3 Quality Manual • Development and maintenance of a formal documented management system • The manual should be fully implemented and supported by documented evidence (internal systems auditing) • Procedures, and where applicable, referring to specification and methods

  22. THE STANDARD REQUIREMENTS • 2.4 Organisational Structure, Responsibility and Management Authority • Authority and communication at appropriate levels • Responsibility of the management • Including clear responsibility of safety, legal, environmental and quality matters • Technical responsibility of product compliance to specification • Details of deputy personnel

  23. THE STANDARD REQUIREMENTS • 2.5 Management Commitment • Top management commitment to the QMS • Importance of meeting customer, statutory and regulatory requirements • establishing the quality policy • Ensuring quality and business objectives are established • Conducting management reviews • Ensuring the availability of resources

  24. THE STANDARD REQUIREMENTS • 2.6 Customer Focus • Top management shall ensure that the customer requirements (and expectations) are determined and are met with the aim of enhancing customer satisfaction • Customers may include: • The immediate retailer • The transporter • The wider community, and consumer

  25. THE STANDARD REQUIREMENTS • 2.7 Management Review • Top management shall ensure that the QMS is reviewed at regular intervals, consistent with the management objectives. • Agenda (may include): • Internal audit • Customer complaints • Production issues • Supplier evaluation of performance

  26. THE STANDARD REQUIREMENTS • 2.8 Resource Management • The company shall determine and provide the resources needed; • To implement and maintain the QMS and continually improve its effectiveness, and; • to enhance customer satisfaction by meeting customer requirements • To provide financial resources required for HACCP study and implementation

  27. THE STANDARD REQUIREMENTS • 2.9 Internal Auditing • Programme of audits in consideration of risk • Senior management approval • Technical personnel • Documented results of audit • Review of audit results • Corrective and preventive actions

  28. THE STANDARD REQUIREMENTS • 2.10 Purchasing • Purchasing information shall describe the product to be purchased, including requirements; • For approval of product, procedures, processing and equipment • For qualification of personnel, and • Quality management system

  29. THE STANDARD REQUIREMENTS • 2.10.1 Supplier Performance Monitoring • The evaluation and selection of suppliers; • Formal evaluation and selection • Approved supplier list (product impact) • Product receipt inspection • Performance monitoring

  30. THE STANDARD REQUIREMENTS • 2.10.1 Supplier Performance Monitoring • Supplier conformance with HACCP • Traceability of product supplied • Verification of supplier claims / approvals • Method and frequency of assessment in consideration of risk • Supplier audits (programme)

  31. THE STANDARD REQUIREMENTS • 2.11 General Documentation Requirements • 2.11.1 Document Control • 2.11.2 Specifications • 2.11.3 Procedures • 2.11.4 Record Keeping

  32. THE STANDARD REQUIREMENTS • 2.11.1 Document Control • Policy statement • Quality manual • Technical procedures and methods • Administration procedures • Supporting records and archives • Reference standards appropriate to the scope

  33. THE STANDARD REQUIREMENTS • 2.11.2 Specifications • Product specification • Product name • Customer supplied specifications • Unique reference / issue number • Authorisation • Availability at point of use

  34. THE STANDARD REQUIREMENTS • 2.11.2 Specifications • The company shall ensure that appropriate specifications exist for: • Raw materials (including packaging) • Completed products (including packaging) • In-process / part completed (where applicable)

  35. THE STANDARD REQUIREMENTS • 2.11.3 Procedures • Production and administration control • Procedure / process name • Customer supplied procedures (and methods) • Unique reference / issue number • Authorisation • Availability at point of use

  36. THE STANDARD REQUIREMENTS • 2.11.3 Procedures • Production and administration control • Process and performance driven • Clear, unambiguous and legible • Issued to appropriate personnel • Readily accessible at all times

  37. THE STANDARD REQUIREMENTS • 2.11.4 Record Keeping • Information and data generated from the QMS • Name of record(s) • Location of record(s) and traceability • Unique reference / issue number • Retention period (legal and/or contract obligation) • Disposal of archive records

  38. THE STANDARD REQUIREMENTS • 2.11.4 Record Keeping • (continued summary) • In line with procedures • Records must be legible and genuine • Safe storage, traceable and retrievable • Contain appropriate information safety, testing, legality and product quality • Computer back-up (as applicable)

  39. THE STANDARD REQUIREMENTS • 2.11 General Documentation Requirements (continued summary) • Reference standards appropriate to the scope, may include; • Food Safety • Compositional standards • Metrology • Additives • Lot identification and traceability • Labelling and packaging information

  40. THE STANDARD REQUIREMENTS • 2.11 Documentation Control (continued summary) • Approved for adequacy prior to issue • Documents shall be authorised • Identification and issue status controlled • Ensure access to documentation at all appropriate levels • Control of customer / supplier documents • Obsolete documentation removed from use • Completed documents and records controlled

  41. THE STANDARD REQUIREMENTS • 2.12 Corrective Action • Investigation of cause • Assessment of risk • Corrective actions completed in a timely manner • Implementation of corrective actions • Review of corrective actions • Verification of actions • Impact - Refer to HACCP

  42. THE STANDARD REQUIREMENTS • 2.13 Traceability • Raw materials • Work in progress • Finished goods • Product identifiable at all stages of production

  43. THE STANDARD REQUIREMENTS • 2.13 Traceability (continued summary) • Raw materials supply • Component supply • Packaging supply • Product re-call at all stages of production • Appropriate reference documentation • Reworking operations control

  44. THE STANDARD REQUIREMENTS • 2.14 Management Of Incidents and Product Recall • Product re-call at all stages of production • Appropriate reference documentation • Testing of the system(s)

  45. THE STANDARD REQUIREMENTS • 2.14 Management Of Incidents and Product Recall • Documented incident reporting procedure • Customer notification • Documented recall procedure • Product re-call at all stages of production • Control of non conforming products • Corrective and preventive actions • Verification of recall systems

  46. THE STANDARD REQUIREMENTS • 2.15 Complaint Handling • Documented system for complaints • Effective management review • Implementation of corrective and preventive actions • Complete records of action taken • Approval of actions

  47. THE STANDARD REQUIREMENTS • 3. FACTORY ENVIRONMENT STANDARDS • 3.1 Location • Location away from “offensive” trades • Maintenance of buildings and infrastructures • Internal fabric to prevent contamination • Boundaries clearly defined • Security of site location • Authorised movement of personnel

  48. THE STANDARD REQUIREMENTS • 3.2 Perimeter & Grounds • Proper drainage • Waste water • Contaminated water / effluent • Storage protected from contamination • Security of the site boundary • Regular monitoring (audited)

  49. THE STANDARD REQUIREMENTS • 3.3 Layout / Product Flow • Process flow to prevent contamination • Operative working space • Cross contamination (biological / chemical) • Laboratory facilities (where provided) • Environmental controls • Washing of equipment

  50. THE STANDARD REQUIREMENTS • 3.4 Fabrication • 3.4.1Walls • Should be appropriate design • Finished surfaces • Removal of dirt, mould, bacteria • Consideration when cleaning of corners

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