PepsiCo Kolkata Plant Food Safety & Quality Excellence Journey 1 PepsiCo Confidential
Kolkata Plant Journey Journey Towards Excellence Kolkata Plant Journey ISO 22K TPM consistency TPM OHSAS TPM implemented. award & CII National Kick off 18001 Excellence AIB Food safety Award Certification Award Unannounced audit Center of ISO Excellence 14001 and (H&S AIB journey started HACCP Certification 2015 2014 Plant Startup 2013 2012 2009 2008 2007 2006 2005 2004 +905 in AIB Unannounced audit 2 PepsiCo Confidential
Food Safety system in PepsiCo HACCP 2006-2011 FSMS ISO 22 K 2012-2015 FSSC 22 K 2016 .. Onwards American Announced GMP inspection Institution of Baking (AIB) Unannounced GMP inspection Quality Program Quality System Health Audit QSHA standard implementation 3 PepsiCo Confidential
A brief about AIB Inspection system NEW SCORING MATRIX <700 – UNSATISFACTORY 700-910 – RECOGNITION OF ACCOMPLISHMENT (With no Unsatisfactory finding) 915-1000- RECOGNITION OF ACHIEVEMENT (With no serious finding) 4 PepsiCo Confidential
AIB GMP inspection – Announced to Unannounced 5 PepsiCo Confidential
Kolkata Manufacturing Excellence through TPM An engaged culture at plant developed through participation by all from each level… It’s plant’s way of life Food safety Quality Plant Quality & Food safety KPIs QM Pillar Approach Identification of Q Expanding QA Integration of food safety More focus on Componen t & and HACCP guidelines activities till Supporting JH and E&T Monitoring through JH food safety under QM - pillar . distributor end: Latent to develop process Standards benchmarking Circle Targets competent operators defect control Focused Task forces Focused approach on Challenging food safety & Quality through QM Pillar approach 6 PepsiCo Confidential
Food Safety Monitoring Tools Circle audits Practice Related Circle audits Monthly Infrastructure Corrective Action plan / System Action Plan Review Circle audits Check Abnormalities Reoccurrence Circle audits Kaizen Maintenance implementation Prevention 7 PepsiCo Confidential
Major challenges Sustenance of Each Day AIB Day Biomethanation Canteen Expansion Sprinkler project Septic tank & Huge man movement PM expansion inside the plant due to project multiple projects Training and awareness (Project and regular manpower ) 8 PepsiCo Confidential
No Unsatisfactory Condition Due To Pest Bird netting done for all RM /Agro / FG docks • No pest related consumer complaint received till date Regular Spray At Plant Exterior By PCI Operators Daily Rodabox Monitoring Sheet Daily Pest-o-flash monitoring sheet Sample Pest Control Spray Log Sheet 9 PepsiCo Confidential
No Unsatisfactory Condition Due To Pest No Unsatisfactory Condition Due To Pest Before Zero bird Before entry Despatch shutter open and entry for bird and other pest incident Closed 40 no of potential openings for pest entry After Second Line Of Defense Prepared to restrict bird and pest During Loading Unloading After Door Discipline, Receiving Inspection & Cleaning Of Pallets On Daily Basis 10 PepsiCo Confidential
Awareness against sources of contamination Daily Tool Box Talk at all project sites Project Display Boards and physical separation CCTV cameras & shoe cleaners at process entry 11 PepsiCo Confidential
Plant Engagement program on Food safety Teacher – student model Food safety related OPLs Slogans & Posters 12 PepsiCo Confidential
Food Safety PEP Talk , OPL Display & Communication 1. Circle Audit 2. Internal audit 3. External audit 4. Other findings Monthly review Food Safety OPL Display At Food Safety OPL Docket Food Safety PEP Talk With Shop Floor . Operatives During Shift Communication Gap analysis Action plan Classroom Training For Food Safety PEP Talk With Training Validation Management Casuals During Plant Entry Class room Communicatio training / on n/ Pep talk/ job training OPL/ Displays Sample Validation Sheet Validation by validation team 13 PepsiCo Confidential
Pla�t’s E�gage�e�t progra� o� Food Safety week & Global handwashing day 14 PepsiCo Confidential
QM Pillar & E&T Pillar _ Collaborative drive - OLC Developing & Uploading Quality & Food safety Modules in OLC ( ON Line Learning Centre ) – Each One Teach One Quality dockets available Quality videos available In online learning center In online learning center AIB training ppt Agro sampling HLE ppt Packaging & palletizing Procedure for potato receiving Personnel hygiene Store Frito-Lay way HACCP module Trim & pair station Storage procedure 15 PepsiCo Confidential
Daily Self Inspection Review – Each day AIB Day After Before Per Day AIB Abnormalities, No of AIB abnormalities 80 85 65 45 Abnormality List 45 Q Was In Decreasing PT 20 25 Tread Within Very 10 Short Time 5 Ave/Day( WK-1) Ave/Day( WK-2) Ave/Day( WK-3) Ave/Day( WK-4) Daily Review With Management Team During Management Wall Meeting 16 PepsiCo Confidential
Engagement program- KPL – QM an integral part Kolkata Premier League – Plnat’s biggest engagement program – QM pillar is an integral part of this program – It is Learning through Fun , powered by Team Kolkata Demo on Q- Defect 17 PepsiCo Confidential
Pla�t’s Kaize� Co�fere�ce – observes Quality improvement & Food Safety related Kaizens – R&R Pratiyogita E kaizen Q1 2015 Sharing kaizen s related to Safety , Quality & Productivity KK – Pratiyogita E kaizen Q2 2015 Sharing kaizen s related to Safety , Quality & Productivity 18 PepsiCo Confidential
Maintenance Kiosk – Tag Management of Food safety related issues is included Posting of Tags prior to sanitation program Categorization of Red Tag & White tag Food safety Tags – priority A and Tech- support allocated to sort out issues QM & PM Pillar Intervention Communication during sanitation day Post Boilout Compliance of Red & White tags are monitored 19 PepsiCo Confidential
Result summary Highest Score First plant to clear in Unannounced Unannounced AIB Score audit audit 1000 905 950 870 900 815 850 760 800 AIB Score 750 700 650 600 550 500 2011 2012 2014 2015 Highest ever score of +905 in 2015 among all food plants in India 20 PepsiCo Confidential
21 PepsiCo Confidential
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