Toward Certification Preparing for the Quality Audit: An Overview Paul Kurrat MBA, M.Ed., CCLP
Welcome! Quality has taken on a whole new level of importance. However, maintaining a high-quality level in a global, complex supply chain has become increasingly challenging. The brand damage that has resulted over the past few years due to low quality products has been substantial. As new processes are created, they must also be managed and measured, causing a ripple effect of challenges. The greatest of these challenges is the maintenance of supply chain consistency. (Fishell, J. 2012)
Achieving Food Grade Certification: We will discuss: Quality Food Safety Management Schemes/Programs What is HACCP? Certifying for Quality Why certify? Primary considerations – Resources How to begin the process What to expect in the Audit What next? Q & A
Quality The standard of something as measured against things of a similar kind; the degree of excellence of something. (Oxford Dictionaries, 2015)
Quality A consistently superior product or service. By creating consistency to a higher standard, we create: Quality, trust, value We become superior when we work to a consistently higher standard. We work to that standard and then : we measure, re-measure and re-establish and perform to a • new standard. We publish that standard and collectively work to a new • benchmark. We create quality from continuous improvement •
Key Words: Quality has taken on a whole new level of importance. However, maintaining a high- quality level in a global, complex supply chain has become increasingly challenging. The brand damage that has resulted over the past few years due to low quality products has been substantial. As new processes are created, they must also be managed and measured, causing a ripple effect of challenges. The greatest of these challenges is the maintenance of supply chain consistency.
Food Safety Management Schemes/Programs FSSC/FS 22000 ISO 22000 BRC SQF HACCP IFS GFSI PACsecure GlobalGAP GMA-SAFE
What Is HACCP? Hazard Analysis Critical Control Point (HACCP) is an approach to food safety that is systematic and preventive. It is recommended by the Codex Alimentarius Commission, the United Nations international standards organization for food safety. HACCP is used by most countries around the world. It has been in use since the 1960s. (Government of Canada Website http://www.inspection.gc.ca/about-the-cfia/newsroom/food- safety-system/haccp/eng/1346306502207/1346306685922 ) HACCP, or the Hazard Analysis Critical Control Point system, is a process control system that identifies where hazards might occur in the food production process and puts into place stringent actions to take to prevent the hazards from occurring. By strictly monitoring and controlling each step of the process, there is less chance for hazards to occur. Source: haccpalliance.org
Certifying for Quality From the Government of Canada Website, There are seven universally-accepted HACCP principles. Every country that uses HACCP follows these principles. Principle 1: The first principle is hazard analysis. At this stage, a plan is laid out to identify all possible food • safety hazards that could cause a product to be unsafe for consumption, and the measures that can be taken to control those hazards. Principle 2: The second principle is identifying critical control points. These are the points in the production process where an • action can be taken to prevent, eliminate, or reduce a food safety hazard to an acceptable level.
Certifying for Quality HACCP Principles continued Principle 3: The third principle is establishing critical limits for each critical control point. A critical limit is the limit at which a hazard is acceptable without • compromising food safety. Principle 4: The fourth principle is establishing monitoring procedures for critical control points. Highly detailed monitoring activities are essential to make sure the • process continues to operate safely and within the critical limits at each critical control point. Principle 5: The fifth principle is crucial: establishing corrective actions. These actions must be taken to bring the production process • back on track if monitoring indicates that deviation from critical limits has occurred. In food production, correcting problems before end-stage production is far more effective than waiting until a product is finished to test it.
Certifying for Quality HACCP Principles Continued Principle 6: The sixth principle is establishing verification procedures. Verification means applying methods, procedures, tests, sampling and • other evaluations (in addition to monitoring) to determine whether a control measure at a critical control point is or has been operating as intended. Verification activities also ensure that the monitoring and the corrective actions are done according to a company's written HACCP program. Principle 7: The seventh principle is record keeping. Records must be kept by the company to: • demonstrate the effective application of the critical control points, and assist with official verification (which is done, in Canada, by the Canadian Food Inspection Agency). Records must be established to document: • the monitoring and verification results, and all information and actions taken in response to any deviations found through monitoring and verification.
Why certify? To meet the demands of an existing customer To improve your status with existing customers To attract new customers Image Shows a commitment to continuous improvement to all stakeholders To reduce the amount of audits per customer To protect the public and your business What are your competitors doing? Government Regulations
Considerations: Resources Is your firm ready for the commitment? Monetary Time Personnel Is your highest level of management committed to the certification? Is the certification sustainable? Is the firm comfortable with turning away potential customers that can impact the certification
The Preparation Process The Plan: No plan, no success. When will you start? When will you be ready for audit? When to audit? Get smart: network your intentions to colleagues, learn about the processes, learn about the challenges Pre-audit: benchmark where you stand Consider core competencies: Hire a Consultant Day 1: Assemble a team Choose a leader for the HACCP team. Very important to ensure the project stays on schedule and to have someone to motivate team members. Consider: skill sets, time, number of processes
The Progress Meet to assign duties, rough dates, rough timelines: Scope of work Evaluate SOPS, maintenance schedules, cleaning schedules Meet again and compare progress, adjust schedule Collate and assemble SOPS into final product for presentation DOCUMENT EVERYTHING!!!! Ongoing: From day one to audit day (and beyond), involve staff, get their buy-in on process improvement. Publish positive changes, share information on why things are changing
Final preparations Mock audit by your team Physical inspection Full mock audit by an outside firm
Audit Day Two or more days of inspection, review of procedures and processes Documents Auditor will review all documents, deadlines for improvements, standards, SOPs, evidence of inspections, evidence of meetings evidence of tracking KPIs. Physical Inspection of facility and/or fleet Half day (or more) of physical inspection Review Review of what the auditor found Deficiencies are forwarded by auditor with required completion dates for repair, or change. Pass or fail
So What? Impacts on you as a: Manufacturer Warehouse Wholesaler Carrier Freight Broker
Formal Food Grade Quality Assurance Program Measurable Consistency that Creates Value and Maintains Quality END! Questions?
Contact Information Paul Kurrat, MBA, M.Ed., CCLP T: (905) 670-9199 Email: pkurrat@globalwhse.com
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