(5 )- Auditing HACCP_Handout (8)

7/27/2019 (5 )- Auditing HACCP_Handout (8)

1/10

Auditing HACCP


2/10

Reminder

Unilever Foods Consumer Safety Framework Standard

General Requirements for Food Manufacture

Guidelines for the implementation of HACCP

(2003)

External

Codex Alimentarius (General Principles of FoodHygiene)

Foods Supplier Manual

Foods Third Party Manufacturing Manual


3/10

Approach- QA Audit

Cover HACCP as early as possible in your

audit Gives you oversight of processes and systems

Enables you to check-off a number of other areas

Get Documents well in advance

It will save you a lot of time on-site

You will appear more professional

You will get to the issues faster


4/10

Key Points- Documentation (1)

Component of the Quality Management System ?

Clear- do you understand ?

Complete- is everything* described fully and accurately ?

Concise- sticks to the point, keeps the focus

Compliant- with the chosen methodology

Current- is it kept up-to-date ?

* The entire supply chain (farm-fork) must be covered by HACCP


5/10

Use of correct inputs- TSDS, GMPs, standards, guidelines &

prerequisites.

Appropriate Terms of Reference and Team

Relevant hazards covered (check GMP !)

Recognised method for identification of CCPs (and disciplinein execution)

Technically & Legally correct limits (that dont force QC !)

Monitoring mentions methods, frequency, person and records

Corrective action that actually protects the consumer...

Key Points- Documentation (2)


6/10

Step HazardControl

MeasuresCCP ?

Crit ical Limi t /

Target ValueMonitoring Correct ive Act ion

Pasteurisation

Survival of vegetative

pathogens due to low

temperature and/or

residence ti me

Aut om atic

Pasteur iser

Cont rol System

CCP

CL:

Time 2 minut es

Temp 72'C

TV:

Time 3 minut es

Temp 75'C

Time: by cont rol comput er

Temperature: by control

computer

Both continuous

If temperature is too low,

flow is diverted until

restored

If t ime i s too short, feedpump speed is reduced

Receipt of Raw

MaterialsContamination

Intake

inspectionCCP

No foreign

bodiesInt ake inspect ion Take appropri at e act ion

MonitoringVagueForces measurement

of foreign bodies?

Specific Specific

All related


7/10

4 Measurements ?

Systems that are in place to preventoccurrence of the identified hazard

Measurement of the parameter associated

with the critical limit or target value

Checking that the content of the HACCP Plan

is correct before implementation

Measurements to demonstrate theeffectiveness of the HACCP system

ControlMeasures

Monitoring

Validation

Verification


8/10

Unrealistic CCPs (1)

Caution- Questioning the judgementof

the auditee will only make things tenseand unproductive !

Unrealistic CCPs can be caused by: weak/hasty front-end risk assessment

lack of understanding of HACCP (especially decision tree)

use of incorrect references to set limits

lack of supply-chain / processing knowledge (what isactually possible)

lack of quality / consumer safety management knowledge


9/10

Key Points- Implementation

Look- compare what you see during your tour against what

is written

Labelled- can you actually find the CCPs in the plant ?

Log-sheets- where do operators record their CCP

monitoring results ?

Loss of Control- ask an operator what they would do when

a CCP deviates

Live- test operator and management understanding and

commitment by questioning


10/10

Useful References

UQAG Website

http://quality.unilever.com

Codex Alimentarius General Principles

of Food Hygieneftp://ftp.fao.org/codex/standard/en/CXP_00

1e.pdf
http://fqag.unilever.com/default.asphttp://fqag.unilever.com/default.asp