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RESPONDING TO DEMAND FOR HIGHER QUALITY TO DEMAND FOR HIGHER QUALITY ... FSSC 22000 IFS SQF ANSI UKAS Others . ... checklist • Water testing + mapping

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An Introduction to GFSI Audits

By Stephanie Lopez

Vice President, Food Safety Services Innovation AIB International

Third Party Audits

An independent assessment of your food safety programs

Benefits:

• Identify issues before they lead to illness or brand erosion

• Identify areas of opportunities for continuous improvement

• Supplier qualification

Global Food Safety Initiative

GFSI

• Launched in 2000

• Harmonizes global food safety standards

• Maintains a benchmarking document

• DOES NOT HAVE AN AUDIT SCHEME

• www.mygfsi.com

“Once certified, accepted everywhere”

Benchmarked Schemes

BRC: British Retail Consortium

FSSC 22000: Food Safety System Certification

IFS: International Featured Standards

SQF: Safe Quality Food

Others: specific to produce, meat, seafood, packaging, distribution

GFSI Audit Components Food safety policy

Food safety manual

Management responsibility / commitment

Management review

Resource management

Document control

Internal audit

Corrective action

Control of nonconformity

Product release

Purchasing

Supplier performance

Outsourcing

Complaint handling

Series incident management

Device calibration

HACCP

Food defense

Product labelling

Traceability

Sanitation

Pest control

Maintenance

Personal Hygiene

Training

Storage and transportation

Allergen control

GFSI Audit Components Food safety policy

Food safety manual

Management responsibility / commitment

Management review

Resource management

Document control

Internal audit

Corrective action

Control of nonconformity

Product release

Purchasing

Supplier performance

Outsourcing

Complaint handling

Serious incident management

Device calibration

HACCP

Food defense

Product labelling

Traceability

Sanitation

Pest control

Maintenance

Personal hygiene

Training

Storage and transportation

Allergen control

Management Responsibility/ Commitment

Senior Site Manager

• Involved in the audit

• Involved in key meetings

• Knowledgeable about food safety programs

• Responsible for food safety and failures

Management Review

Regular meetings

Report on status of the business

Report on objectives

Corrective actions for continuous improvement

Audit results Complaints HACCP Incidents Process deviations New science New legislation

Document Control

All policies, procedures, records

• Master list of documents

• Revision date

• Revision history

• Approval

• Procedure for rescinding obsolete documents

Document Name: Authored by: Document ID: Approved by: Effective Date: Page: # of ## Supersedes Date:

Internal Audit

Review of entire food safety system

Trained audit team

Auditors independent of area audited

Interviews and inspection

Document and record review

Conformance and non-conformance

Corrective and preventive action

Following our plan? Is it effective? Does it meet GFSI requirements?

Serious Incident Management

Crisis Management Plan • Recalls • Natural disasters • Regulatory investigations Includes: • Resources (legal, scientific) • Product disposition criteria • Facility disposition criteria

Preparing for a GFSI-scheme Audit

• One year to prepare

• Fully compliant 90 days before the audit

1. Study the standard

2. Gap assessment

3. Internal audit training

4. Pre-Assessment (or second gap assessment)

5. Audit

6. Close non-conformances

7. Certification

Which certification to chose?

- Be part of the GFSI program

- Fit with current QC programs

- Be in line with current operations and business practices

- Chose certification body that is recognized by your customers

3rd Party Decision Chart:

1. Search GFSI scheme

2. Estimate “best fit” which existing QC program

3. Order the Standards + Interpretation guideline and study it

4. Start your to do list

5. Create timeline and budget

Investing in BRC certification:

- Administrative tasks: procedure writing ….

- Training staff – meetings – follow through

- Building structural changes

- Equipment purchase/upgrade

- Pre-audit: practice before the game

QC supervisor/ manager salary

Production TL/Supervisor training time – staff meeting time

Walls/ceiling renovation – changing rooms reno – new drains - …..

New Lab equipment – floor testing equipment

Pre-audit: $4,000-$6,000

Vermont Creamery path to BRC:

Selection GFSI scheme

Select certification

auditor

Pre-audit preparation

Pre-audit

BRC 1st accreditation

audit – GRADE B

BRC 2nd annual audit –

GRADE B

BRC 3rd annual audit –

GRADE A

2013

2012

Oct 2011

Aug 2010

March 2010

Jan 2010

Nov 2009

Vermont Creamery BRC Implementation:

2. Food Safety Plan – HACCP:

• HACCP team

• Product Profiles

• HACCP flow charts

• Hazard analysis – decision chart

• HACCP deviation report

• Record retention policy

• Raw material hazard analysis

Vermont Creamery BRC Implementation:

3. Food Safety and Quality Management System

• Quality document

• Quality manual

• Internal GMP audit

• Supplier approval program

• Inbound-outbound truck

• Lab SOPs, COA

• Ingredients, Products

and packaging program

• Make sheets

• Corrective/Prevention Action Plan

• Hold and Release procedure

• Mock recall

• Customer feedback records

• Business continuity Plan

• Incident Management team

Vermont Creamery BRC Implementation:

4. Site Standard • Local Hazard Identification • Food Defense Plan • Process Flow map • Security system • Raw product in fully enclosed

dairy pipes • Walls and physical separation • Drain maps • Glass and Brittle Plastic

checklist • Water testing + mapping

• Equipment Hazard analysis • Preventive Maintenance

Program – work orders • Non-Food grade

chemicals/lubricants storage policy

• Sharp tool policy • Wood policy • Metal detector • Pest control Program • Temperature Alert System

Vermont Creamery BRC Implementation:

5. Product Control • Shelf life evaluation • Allergen program, ingredients spects, supplier approval program • Cross Contamination policy • Packaging verification • Finished Good testing program • Lab data recording program • Calibration program

Vermont Creamery BRC Implementation:

6. Process Control • Make sheet • Chart records • State calibration: HTST, Vat pasteurizer • FG verification program • In-line weight verification program • Calibration schedule

Vermont Creamery BRC Implementation:

7. Personnel • Employee training program • Training records + quizz • Hand washing procedure • GMP training • Visitors program • Unifirst - workwear program • Gloves program

Global Food Safety Initiative (GFSI)

Food Safety System Certification 22000 (FSSC 22000)

Robert Frie

Plant Manager Emmi Roth USA

About Emmi Roth USA

• Emmi - International Company HQ in Switzerland

• Emmi Roth USA – Originally founded in 1991 in

Monroe, WI as Roth Kase

– Purchased by Emmi 2011

– Mfg Specialty Cheeses and Fresh Dairy products

– 4 manufacturing facilities in the US (California, Wisconsin, and New York)

– Approximately 400 employees

The Journey Begins……… • Management’s commitment

– Absolutely begins here!

– Non-Negotiable

– Must be involved & participate

– Must talk the talk & walk the walk

– Must act on the need for Improvement

– Must LEAD the change in culture

• Lead by example – your Brand and Company are worth it!

Decisions to be made

• Which Scheme to chose – BRC, SQF, FSSC 22000, etc.

• Which accredited body to chose – AIB, SGS, Silliker, etc

– Is there training available?

– Costs

• Time line – Pre Assessment

– Employee training

– Certification

– Resources

Which Standard should we implement?

• Research the standards to see which one fits your company’s needs.

– Certification timeline

– Training needed / available

– Costs

– Labor/Resources

– Customer base acceptance

– References

2014 Aug Sept Oct Nov Dec 2015 Jan Feb Mar Apr May June July Aug

SepS

Kick Off

EVENT

Form

Food

Safety

Team

GFSI

scheme

and CB

Planning

Gap

Analysis

Create or

Review and

strengthen

your

HACCP

Education

and

training on

the

standard

Certification Timeline

Create

Food

Safety

Policy

Certification

Audit!!

CELEBRATE

Internal

Audits

w/CA

Food Safety Team routinely meets – continuously improving

Training of

FST and

Internal

Auditors

Education

and

training on

the

standard

Internal

Audits

w/CA

Internal

Audits

w/CA

Internal

Audits

Begin

w/CA

Re-assess

Gap

Analysis

Pre-

Assessment

Audit

(w/CA)

Continuously

Developing

• Lack of Management support – It’s not a “PROGRAM” with a start and stop – Not leading the transition in culture change

• Lack of resources – Not enough people man hours – Too many hats being worn

• Implementation timeline too aggressive – Corrective actions vs band aids – Allow yourself time to build a structured food safety system

• Understanding the standard – “Shalls” – Showing objective evidence (young system vs established)

• GAP analysis was poorly done – Allow enough time to perform

Challenges with GFSI Audits being “recognized”

• 3rd Party Audits – Silliker

– Perry Johnson

– Cook n Thurber

• Customer Audits – Walmart

– Military

– Schreiber

• State / Federal Audits

• “other” ISO Audits

Evidence of a Food Safety Culture

Evidence of a Food Safety Culture

Evidence of a Food Safety Culture

Food Safety is Transparent!

• Avoiding illnesses and deaths

• Sharing information and successes

– Synergies

• Safeguarding the supply chain

• Brand protection

• Continued success of your company

• Saving resources and money

Create the food safety culture you want to see

You had better be

making SAFE

Cheese boy!!

Final words

• The 7 P’s

– Prior

– Proper

– Planning

– Prevents

– Pretty

– Poor

– Performance

Retailers who recognize GFSI benchmarked schemes in their supply chain

• Burger King

• Campbells

• Cargill

• ConAgra Foods

• Danone

• HEB

• Hormel

• ICA

• Kraft Foods • Kroger • Loblaw • Maple Leaf • McCain • McDonalds • Pick-n-Pay • Publix • Raley’s

• Raley’s

• Shop Riter

• Sodexo

• Coca-Cola

• Tyson

• US Foods

• Walmart

• Wegmans