Foundation Degree (FdSc) in Food Manufacturing Management Essay Example for Free

Foundation Degree (FdSc) in regimen Manufacturing oversight EssayIntroduction examine objectiveswhy Audit?The intentions of this Audit atomic number 18 as followsUsing a recognised GMP sample (UNIDO/BRC) measure go forth and quantify the durability of the current timber body that is in go forth.Recommend, upon survey, strategies for approach that tidy sum be do to meet, and potenti anyy exceed, the minimum retail requirements.* Upon mop up, altogetherow the barter to great deal attainable goals and objectives in golf-club to become the line of drub forward. This is in an efficiency, action and legal capacity.Company ProfileShetland SeaFish (Hull) exceptional started trading in 1922 as a specialist maker of frozen fish products. The gild employs 50-60 round on site and has a total of 80-100 employees fetching through issue the group. The group has three factories. The new(prenominal) two be involved in primary accomplishing and fish farming in the Shetland isles. The party supplies super grocery stores, discounters, fish wholesalers, frozen nutrition for thought distri butors and forage for thought service companies. The principal(prenominal) market is the UK but the company in addition has a sm whole export trade. Shetland SeaFish (Hull) particular has implemented a tightly bookled musical arrangement of operational procedures including a fully documented HACCP system and quality manual.Business EnvironmentThe nutrient industry is one and only(a) under pressure. The fishing industry in special is an theatre with its own particular problems which stir a direct impact on this company as fish is its primary raw hearty.Over the past a few(prenominal) years, environmental concern over diminish fish stocks has contributed to attachd governmental interdiction to manage fishing quotas. Although this may be the case for the content fishing industry, the world wide catch (up until recently) has been on a stead y rise. This company sources raw material from worldwide locals (Particularly the Asiatic beas such as China and S stoogedinavian Seas) so the impact has been minimal.The dash in which the company sources fish may change in the future, as inter pass auctions atomic number 18 on the increase, and this makes the market much of a volatile entity as prices potful fluctuate as events affect fishing procurement.The causation(a) main problem with the aliment industry is the strength of the major multiples over the manufacturers. The major supermarkets to whom close to fargon manufacturers supply, aim to proceed a constant gross profit margin which is typically quite large. To glisten this, the multiples like to pass down on-costs to the suppliers. Offers such as subvert one, apprehend one free ar fuelled by the manufacturer, and come straight from their bottom line. By enumerationning a BOGOF offer, it is affectively selling the product at half the unit price for the durati on of the offer.One supermarket that this company has dealt with also deducts (on their own accord) a stupefy price to go towards advertising and marketing. For example, a deduction of 10,000 baron be deducted from an flier to them for product, with the debateing organism that even if that come up is non being utilize to directly promote that particular product, erect by advertising the stores in general, the increased list of nodes flowing through the store, should they say, increase sales to the companys product. This deduction from the invoice is im work overd by the supermarket, and beca part you do not know how a great deal they are passing to do this, it makes cost for condescension more difficult.Combine this with the fact that at every price examine by the supermarket buyers, they fill higher quality products, for a reduction in unit price, depresses margins lower than ever.The margin depression brings with it a set of problems. Beca intent a company has to r educe its costs to meet the price meridians per units, so as to maintain the business with the supermarket, it makes it for a business to remain as profitable as what it would like to be.A littler margin means that a company does not carry the same measure of free smashing available to it to make necessary re-investments which would help to procure more sales and increase throughput. In persona quad of the overview, a ad hoc study of this is discussed in relation to an OEE study on one of the factories lines. at that countersink are several technological resolutions available which if purchased would go a bulky way to increase productivity. alas there are several financial constraints which place barriers to the procurement of these technological improvements. A brief intervention of Chicken and Egg barriers is briefly explained in section four of the overview.The problem lies in the fact that if a new piece of equipment is subscribe toed to continue, or to improve pro duct, whence the company does not commit bountiful liquid capital available to be able to purchase it outright. This means that the company would befuddle to check up on borrowing facilities.The problem with this is that the company would like to have a secured amount of business from one of, or a combination of customers, in order to dupe on the risk of borrowing large amounts of money. The reason for this is that a company has to account for a payback period into their costing to cloak borrowing and participation as well as machine depreciation.With deadened product placement tenures, the guarantee of continued business for this period is not there, inhibiting the business from wanting to ask a risk of this magnitude. Eventually a company has to bite the bullet and take a risk in order to increase turnover and throughput. little margins also mean that there may not be enough of an increase in net profits to cover supply requirements. Each year there is a general staff approximation to discuss the terms of wages and conditions. If the company is reduced in its profit capacity, then this trend is often relayed onto the takeforce.f the company has diminished available finances then money is not possible to cede staffs the annual increase in wages or to be able to invest in common facilities.This has a knock on effect on staff morale and motivating if the annual increase is postponed or if it has to be pottycelled. It manifests itself in somewhat(a) somebodys in a revenge motivation mentality. As the individuals ol milling machinery modality aggrieved beca occasion the company cannon admit with what the workers feel is a basic right, then they may wish to get back at the company.At best this may just be by reducing their amount and quality of work, therefore their loyalty is affected. At worst, it could be resignation, dissention or even some form of industrial sabotage.Without the increase in wages rates it also lessens the difference among st that and what the government sets as the discipline minimum wage. This poses a problem in relation to retaining, and gaining new employees.At one suggest, working(a)s(a) in a milling machinery used to attract a premium, but over time that has decreased to the point to where wage levels between shop workers and factory workers are almost the same.With the current work ethos among new employees (particularly newfangled people) the dilemma of where would I like to work arises. Either a (usually) smelly, shift work system, hard work inducing factory, or a shop, where they can go straight out from without having to go home for a shower and change, is less hard work and usually has a set nine until five work pattern. For the same, or similar, wage, most people appear to want to work in a shop.This displays a different shift from employment trends from primary or secondary employment to a absolute majority of employment in the tertiary, or services, sector.If a company has a h igh turn-over of staff, then generally the quality of staffs decreases. This may then affect production make and efficiencies.One way that this can be combated is though an increase in staff tuition. This not only acts to some(prenominal) increase staff quality, but it also helps to improve the individuals hypothesize satisfaction. This is through increased competency, increased knowledge (i.e. making an individual more multi-skilled) and the feeling that they are not in a dead-end job.In the industry sector to which this company falls, there is an increased amount of governmental grants available for staff provision programmes.Within this factory, all of the employees of beginning(a) tier level have all been through NVQ level 2 training in nutriment hygienics and handling. Production supervisors have received additional training to NVQ level three in this area. in that respect is also a begin of other courses that are being studied that are part funded, or reimbursed by, g overnmental policies.It is clear that there are some relatively easy ways to increase the efficiency and line throughputs of production. Unfortunately constraining factors come into play to inhibit potential growth as long as margins are squeezed picayuneer and smaller.This is a self perpetuating cycle. If allowed to make a little bit more profit then this can be channelled back into the business to increase production efficiency and overall turnover making the business more successful.Legal Issues on that point is a complex mine field of enactment that comes into play when dealing with a food unit operation. on that point is a whole plethora of acts and regulations which help to control the food industry which helps to value the consumer from dubious consecrates and ensure that the final product that is consumed is of the expected centre of attention, nature and quality demanded.There are several levels of legislation* make believes, which are statutes passed down by par liament.* Regulations which are make under particularized acts* E.C. directives which are passed down from the E.E.C.The Food gum elastic device enforcement officers have various enforcement powers which enable them to ensure that all of the legislation is correctly adhered to. These can be servicing notices, sampling and seizing foodstuffs, and also to instigate criminal proceedings if an offence is made.The main legislation affecting this business are to be listed as followersFood Safety Act, 1990This act is in relation to the sale of food for human consumption and is applicable to all food exposit.This act makes it an offence to* Render food injurious to health* Sale or obstinance of food injurious to health, or that is unfit for, or is contaminated.* Sale of food that is not of the correct nature, substance and quality demanded by the consumer.* Give any false or misleading descriptions.The Food Premises (Registration) Regulations, 1991 (SI no 2825) amended 1997This re gulation requires all food exposit to register with the local, or port authority, in the area that they are situated. Every registration authority mustiness oblige a register, which can be accessed by the public for command.Food Safety (General Food Hygiene) Regulation, 1995 (SI. no. 1763)This act provides general requirements for all food apportionrs and premises (with specific requirements for preparation areas, moveable and temp. premises, transport, equipment and the like) to be unbroken clean, facilitate make clean, and prevent the accumulation of dirt. It also specifies a requirement for all food premises to happen upon all steps in the business that is minute to food arctic, and to minimise these risks.The Food Safety (Temperature authorizations) Regulations, 1995 (SI. No. 2200)This determines any matter involving a risk to food safety, in relation to the nature of the food, manner in which it is handled and packed, and processes and conditions under which it has been displayed or stored. No person should maintain food that is likely to support the growth of pathogenic bacteria or the accumulation of their toxins.Products of Animal start (Import and Export) Regulations, 1996These regulations govern the origins of animal foodstuffs from countries outside the EEC. Since 1993, foodstuffs imported from other members of the EEC are not liable for inspection due to the open border policy, but they are still subject to the Food Safety Act 1990.Food Labelling Regulations 1996 (SI. No. 1499)These require most foodstuffs that are to be sold for human consumption be labelled with* The name of the food.* List of ingredients (Quantifying ingredients mentioned in the name of the food).* Best before dates, which direct minimum intensity level or perish ability of the food in relation to microbial or product debasement beyond being fit for human consumption.* Any specific remembering conditions necessitate.* Name and address of the manufacturerThe Qui ck-Frozen Foodstuffs Regulations, 1990 (SI. No. 2615) amended 1994Food that has undergone quick-freezing (i.e. whereby the zone of maximum crystallization as rapidly as possible) should be labelled as such. It must be suitably packaged so as to protect it from microbial and other pollution and also to protect from de-hydration.Must be labelled with* BBE* store requirements including temps.* plenteousness reference* A clear message not to refreeze after defrosting.There are also some specific legislation relating to food poisoningPublic wellness ( lead of Disease) Act 1994The Public Health (Infectious Diseases) Regulations, 1988 (SI. No. 1546)National Health Service (Amendment) Act 1986The National Health Service (Food Premises) Regulations, 1987 (SI. No. 18)The Public Health Laboratory Service (PHLS)These pieces of legislation relate to reports of incidences of food poisoning and food borne illness. It empowers officers to investigate food premises on the basis of risk to increas ed infection, and to identify the source of food poisoning illnesses.Separate to food related issues there are also a number of other pieces of legislation that apply to most businesses. These areHealth SafetyThe Health and Safety at Work Act 1974The Control of Substances dangerous to Health Regulations, 1994 (SI. No. 3246)The Reporting of Injuries, Diseases and Dangerous Occurrences Regulation, 1985 (SI. No. 2023)The Electricity at Work Regulations, 1989 (SI. No. 635)The Management of Health and Safety at Work Regulations, 1992 (SI. No. 2051)The Workplace (Health, Safety and Welfare) Regulations, 1992 (SI. No. 3004)The Personal preventive Equipment at Work Regulations, 1992 (SI. No. 2966)The Manual Handling Operations Regulations, 1992 (SI. No. 2793) all told of these laws are in relation to withholding equipment in nice order provide all PPE, also in good order, and to report all accidents and medical problems caused by/ at work.There are some new environmental legislation in relation to waste water and effluent, and also the climate change levy.There are also waste land fill laws (After B.S.E. and Foot and Mouth no food wastes can be further processed into animal feeds)It is clear that there are a lot of laws that help to keep the consumer, and employees safe, both in relation to food safety and personal safety. In order to comply with all of these laws, and check with the companys compliance to these, the office of fair trading and the environmental health office audit the factory on a unshakable basis.Section2Key FindingsSummations on Audit checklistsSection by section reviewHACCP SystemThe company has a very pointed and comprehensive HACCP system following the Codex principles and based on risk assessment for apiece product type.The latest revision is June 2002. The HACCP reinforcement includes Introduction (Intro, group, product description, intended use, flow diagram, and verification of flow, controls and hazards), Process flow (product, pr oduction process), Hazards, Hazard analytic thinking and Hygiene controls.The site technical manager who is qualified in advance food hygiene leads the HACCP team. The other HACCP team members include the production manager, financial director, business consultant, Q.A. supervisor and HS officer. They have all received training in HACCP principles.Eight CCPs have been identified and understandably marked round the site. These include R.M. intake, band power saw room, product storage, packaging storage, coatings, behave making, behave buggies, sauce deposition and metal detection.Shetland SeaFish (in conjunction with Cravenglow consultant limited) has produced a handbook for employees entitled Understanding HACCP and the British Retail Consortium Quality Award. This book was issued to all staff before going through their first successful BRC audit, and is issued to new staff during induction. The Handbook explains HACCP terms and working practices, details the eight CCPs, How to control potential Hazards, How HACCP works, Different types of Hazard, other valuable HACCP information and an introduction to the BRC standardQuality Management SystemThe site operations/quality manual has been fully implemented and index numbered in the latest revision (Revision 4 October 2002) to the BRC technical standard version three.Policies and procedures reference to the HACCP manual and currently cover all of the identified critical controls.Each working area has its own handbook that includes some or all of the followingFactory alter proceduresTechnical termsKey staffSafe working practicesFactory proceduresQA procedures applicable to the area.A specifications file maintained by the company has a programme of sexual audits that cover the entire quality system twice per year.The handling of complaints is the responsibility of the Technical manager. Complaints are referenced individually, by customer, and complaint type. Corrective actions arising from complaints are degradeed.An approved supplier list is in operation, deliveries assessed at intake, and supplier performance reviewed quarterly. One of the key findings of this audit has been that although the supplier audit plans clearly defined and laid out, it has not been adhered to. This haves rectifying by the time of the next audit.Factory Environmental StandardsThe factory is well located just off the main route into Hull, and has a logical process flow.The buildings are well constructed. Walls panelled with false jacket crown and smooth concrete stages.Equipment is industry standard and is be well maintained. There is a planned charge system administered by a well-resourced engineering department. provide changing facilities are provided by separate storage of work wear and personnel wear with staff locker rooms situated well aside from production. Work clothing situated in changing facilities on the entrance to the production facility.A consecrate night hygiene crew operate a comp rehensive make clean programme, verified using bioluminescence adenosine triphosphate swabs. This form of assessment is under utilised. By conducting more swabs, a more indicative trend abstract can be compiled. This system could also be drawn-out to coordinated hand swabbing, so as to gauge the impressiveness of the staffs hand washing.A comprehensive pest control contract is in place with Rentokil and no infe order reported. The only addition to this regime would be to introduce catch tray synopsis. This is not do at present, although Rentokil have been asked to provide a quote for the service. The reason that catch tray analysis is so all-important(a) is that various indicator species of insect may help to identify a particular problem in entres the factory. other option is that the accountant is a qualified entomologist. The suggestion has been made that they complete the catch tray analysis on behalf of the company.Transport and waste removal are both contracted out services.Product ControlThere is a product development procedure detailing the process steps and documentation held for customer driven development work. Development work is mainly restricted to crumbs, batters and sauces and as such, the suppliers of these materials carry out a lot of the work.Product is analysed on line hourly by trained QC staffExternal chemic and microbiological analyses are carried out at a UKAS certify immaterial laboratory. The result turn around is typically ten days. There is an investigation into the possibility of bringing the microbiological test into a feasible in-house solution. The testing procedures pet are the rapid methods that are now available on the market. These allow for rapid enumeration and recognition in unprecedented speeds compared to traditional plating methods. Because of the simplicity of the tests, it reduces the degrees of error that might be socialise in old style methods, and also it helps to simplify the lab quality manual. All of these rapid methods are AOAC accredited methods and are thus suitable for ISO 17025 standards, which is a pre-requisite for the accreditation edicts stated for BRC compliance.Products coded to allow stock rotation, and on-site stock levels kept to a minimum. The cold store has the capacity for approximately 600 pallets, which are on a mobile wrenching system.Metal detection is carried out on all products at 3.5mm non-fe and 3.5mm fe. Legislation is on the way to incorporate testing using S. Steel rods as well, using the same sensitivity levels.Product is released based on on-line QC testing. A non-conformance procedure is used to prevent the despatch of non-conforming product and its restriction to quarantine.Process ControlControl of sauce cooking and processing is closely monitored by QC and thermographs are in place to maintain sauce cooking profiles.QC also regularly verifies process parameters and freezer temperatures. Continuous quantity control supervise equipment is in place on the coated fish line.Check-weigh systems are calibrated at the start of severally day following a detailed calibration procedure.Hourly QC checks and unremarkable taste panels verify process parameters and specifications requirements have been fulfilled and all measuring equipment is calibrated at appropriated frequencies.A small amount of kosher product is processed on site and the delivery processing and despatch of kosher materials is closely monitored. forceStaffs trained to NVQ levels 1 and 2 in hygiene and safe product handling by external consultants. Plans are in place to introduce an in-house training scheme. The Q.A. supervisor holds a CIEH certificate of Advanced Food Hygiene. Once they complete the CIEH professional trainers certificate, it will allow them to train new staffs, and re-iterate to current, basic food hygiene and HS.Hygiene rules are also available in the staff handbook, given at induction.Induction includes hygiene and HS requirements, fire drill procedures including a tour of the facility (highlighting emergency exits), company objectives and the review of the individuals accountability level.Staff and visitors complete a basic medical questionnaire before entering the factory.Protective clothing provided and laundered by bear based in Hull and only specialising in laundering of food industry clothing.Supervisory staff and line leaders trained to NVQ levels 3. Detailed training records are in place, but not review on a frequent basis.Section3Improvement strategyRecommendations on enhancementWhy did it fail? What can be done?The overall result of this audit is promising. The main sections that are in need of improvement are the cleaning and management systems.With regards to the cleaning controls one of the biggest deficiencies is that there were no daily cleaning logs in place at the time of the audit. These are necessary to verify that all of the pieces of equipment that has been used during the course of the produ ction shift have been cleaned efficaciously. This should also incorporate a list of equipment that ineluctably periodic or monthly cleaning, similar to the engineers protective maintenance system.Provisions are in place to indicate cleaning frequency, but by combining this with a daily cleaning log a system of records can be obtained to help with any Due Diligence defences that might need to be called into play. The tour step to reduce the microbial and soil loads within the factory are the cleaning inventorys, but the due diligence defence are the daily logs. These are a record confirmation that the schedule has been implemented, and also provides accountability of who conducted the particular action that might be in question. It also helps the management team to assess the manning levels involve for a particular cleaning regime.By combining these logs with an effective utilisation of the Lightning adenosine triphosphate hygiene verification system it would be possible to mor e accurately monitor the effectiveness of the cleaning systems that are in place. At present the unit is not used at levels that are going to supply the monitoring team with a set of results that are statistically significant. By increasing the levels of testing with the unit, a better picture of cleanliness levels can be obtained by using the trend analysis bundle to scrutinize past results and to predict problems that might occur in the future.This system could also be extended to apply to incorporate hand washing checks. This could be done on a random set of checks throughout the week. It might be possible to correlate this to the expected and substantial bacterial soap usance rates to see if there is a relationship. This might be an extra way to monitor the effectiveness of the staff in the own personal hygiene in relation to hand washing.The engineers need to keep an inventory of parts as a indemnify is carried out so that all pieces are accounted for upon completion so as to eliminate the possible physical contamination problem, or at least to identify if there is one.A number of hose pipes were observed around the factory, liberally strewn on the floor. This is not unstable GMP it also creates an impression of untidiness and not caring for not only visitors, but also to other staff. Perhaps the purchasing or some hose reel storage units. If these hoses were kept on one of these units, it would automatically reel in and is then kept neatly on the wall, off the floor and out of the way of people walking around the factory.During the course of the audit the food waste skip was leftoverfield(p) open. This leaves the inlet open to many potential problems. The first is that it has a potential to attract pests. By going the skip doors open is may provides a food source for advantageous vermin.It was observed that there were some birds on the fence which might have been attracted by the residue border the skip. To eliminate this problem aspect of a reaching handle for the skip door should be made.By keeping the skip door closed it prevents vermin from entering the skip to scavenge for food. With the skip door closed, thus stopping pests from gaining a free food store, the area around the skip must be kept clear also otherwise keeping the door closed is a futile effort.This area not only needs to be swept, but also cleaned down with a detergent to emulsify the fatty residue left from the batter scraps. This would also help to make the area safer for the employees as it would make the area left given up to causing slippages, and this is especially important as there is a small set of steps out there.There is no provision for persons to wash their hands upon re-entering the factory after going to the food skip. There person would have to go to the basins outside the packaging area. A small basin or alcohol station should be installed to prevent this.The main body of the factory was in very good condition. There were a few incid ences that need to be rectified in order to improve the grade.Around the sauce making area, the hood tiles preceding(prenominal) them had some signs of mould growth. This is an indication that the ventilation is perhaps inadequate for that area. some(prenominal) form of steam ancestry unit might need to be investigated in that area. In the misfortunate term, regular cleaning with a sterilizer (with some form of mould growth inhibitor) would suffice, but this would only deal with the symptoms, and not deal with the route cause.The sauce agitators in this area are in need of recovering. The motors on the agitators have some small areas of paint flaking from them. Even though the paint is blue in colour, it provides a potential physical contamination problem. This needs to be tackled in several ways.The first and easiest to do is to recover the motors. The motors can be covered with a stainless steel covering which would prevent both paint flakes falling into the sauce, but also d irt accumulation on the motor.Another method is to use an alternative agitator motor. There are several on the market, and several of these are not mount directly above the sauce making kettles.There are also some other methods for sauce production, that if increased production were to be required, then they should defiantly be investigated.Another area in the factory that could benefit from additional extraction/ventilation is directly surrounding the coating line. When the fryer is producing breaded products, then the first stage crumb, which is a fine crumb, causes a lot of dust to be blown in the air. This causes lush dust accumulation on the pipe works above the fryer line. This needs additional cleaning to remove the dust in this area. Perhaps a form of extraction system should be investigated in this area.As a minor point, there was also a small pool of water surrounding the con-air compressor units. This implies that the floor does not bevel in the right direction. Again th is is a stead that has a long term objective, but also has a short term measure.The long term goal is to re-lay the floor in that area to make the floor slope in the right direction (i.e. from the wall to the drain). The short term solution is to have the cleaners regularly squeegee the floor of water.Standing water is a particular problem in that it provides excellent breeding ground for Listeria spp. Bacteria. Listeria is a food borne bacteria that is by nature found in the environment. By providing pools of standing water, it magnifies the problem and opens the potential for increased incidences of Listeria monocytogenes poisoning.It is a strange practice that although there are manager and team leader meetings on a regular basis, there were no supervisor meetings held. This is a gross deficiency, not for GMP, but for the lack of communicational strokes that are missed from these meetings.By conducting these meetings a intercourse can be maintained between the higher levels of management and the junior levels. During these sessions company objectives can be relayed, problems considered, and grievances examined.It is also an excellent opportunity to provide motivation to the staff and to keep them apprised of important happenings within the company, such as potential sales, production turnover, NPD and the direction of the company. These meeting should be implemented effectively immediately. If not in their own right, then try combining the team leader meetings. This may pose a problem with truthful communication if the team leaders feel inhibited by the carriage of the supervisors, especially if they have any grievances with them.The omission of the supervisor meetings exacerbates the next point. That is the cut crosswise communication of ideas and bids between departments. This point is discussed in more detail in the second overview of the audit.The job descriptions that are in place for the key positions within the factory are deficient in the tota lity. I would suggest a review of these be taken with the specific aim to include the individuals main duties and responsibilities, full accountability, and any health and safety requirements that are obligatory to know.By providing a comprehensive description it helps the individual to identify their own proficiency against what is expected of them. It would also help to identify any training needs by comparing what the individuals actual abilities to what is needed for that position. During an appraisal a gauge of competency can be made against the standard and a measure of feedback can be relayed to the person.This also ties into the fact that no records are kept of personal record reviews. These need to be conducted on a regular occasion, and if they are being conducted at the moment, then they need to be recorded.There are some clear objectives that have been identified and now need to be applied and rectified to improve the factory as a whole.Section4ConclusionsOverview of pr ogression stratagems pervert by step guideStructure and Fabric* Hand washing basin/ alcohol station to be installed by exit to food skip.* Foods skip needs to be looked at and a handle constructed to enable the lid to be closed.* Sauce kettles needs to be looked at for possible installation of extraction units.* Sauce agitator motors needs to be covered to prevent paint flaking into product.* Hose pipes to be displace into self reeling units.* Pool of water needs investigating around con-air units. Floor needs re-laying in that area.* dot accumulation above fryer area. Additional extraction needed.Pest prevention* Pallet shed door needs to be kept closed. Pallets stored away from walls in storage.* Some drain covers missing and needs replacing.* overhaul tray analysis needs to be done.Cleaning systems* Daily cleaning logs introduced.* Engineers inventory of parts during a repair to prevent contamination.* Effective utilisation, and expansion, of ATP hygiene monitoring system.Mana gement Controls* Introduction of supervisor meetings.* Additional training to supplement and increase knowledge of GMP systems, Food hygiene and legislation.* Review of job descriptions.* Record employee appraisals.Section5ReferencesBackground / further reading.Including bibliographyHygiene for Management, Sprenger. R. A. 1998 (8th Ed)Cleaning, Dillion M, et alInspirational Supervisor, Shaw J. 1999FdSc Food manufacture management GMP Course work notes, Dillion M. 2002Log bookOverviewsOverviewsPart 1 Basic findings from two sections of the manual.Section 1 Structure and double-dealingThe factory has a logical process flow and the buildings are of sound construction. All internal factory wall surfaces are panelled with a lowered false ceiling and smooth resin floors. Equipment is industrial food grade standard and appears to be well maintained. A preventative planned maintenance system is in operation and resourced by a competent engineering department. The work wear is situated in a separate clean changing area immediate on entrance to the production area. The pest control is out-sourced to Rentokil (initial services) with no signs of infestation problems to report.OBS 1 The floor is made of an impervious material and when combinations of two immiscible liquids (such as oil and water) mix, it causes some sections of the floor around the fryer area are slippery.Recommendation Review the cleaning schedule for this area to include a protocol stating that the floor in that area is to be cleaned as often as required throughout the production day, in addition to the usual scheduled cleans. Another suggestion would be to use a floor covering/mat to make the area more non-slip.Timescale 30daysOBS 2 There was a small pool of standing water around the con-air units during production.Recommendation The long-run goal would be to re-lay/repair that section of floor to provide an adequate slope to provide water run-off into the drainage channels. Action to be taken pla ce in the mean while would be to order the cleaning schedule to include that the area is to be cleared as often as required throughout the production day.Timescale 90 daysOBS 3 There was no steam extraction above the sauce making kettles handsome rise to N/C1.N/C1 Evidence was noted by poster and noted, audit checklist ref GMP Section 1 -ref 1.8.2, that there was the beginnings of mould build up on the ceiling tiles above the sauce kettles.Recommendation Investigate the possible methods of fume extraction best suited to the needs of the task. Possible installation of an extractor cowling. Action that can be introduced quickly is that a revision of the cleaning schedule to include weekly/fortnightly/ or as required cleaning to be undertaken in that area using a detergent with mould growth inhibitor.Timescale 90daysSection 2 Storage FacilitiesStorage or R.M, WIP, finished goods, packaging and tainting elements are well segregated with observed codes of practice to prevent cross contamination. Products are coded to allow stock rotation on a FIFO basis and the stock levels that are kept on site are kept to a minimum. There are no contractual off-site storage facilities used. Products are released on the basis of on-line QC testing. Procedures are in place regarding damage or defective goods segregation and disposal.OBS 1 Only visual checks are made of the contracted out logistics companys vehicles.Recommendation Revise an audit schedule to visit their head office so as to not only audit the vehicles used for the transportation of goods, but also to review the company policies and procedures regarding GMP practices.Timescale 90daysPart 2 Area to improve.The area of greatest need is management control, especially in relation to motivation of staffs and inter-departmental communication. A highly motivated workforce can increase the potential output efficiency greatly, without the need for pricy capital expenditure.Poor communication is the catalyst for futu re problemsJohn Shaw, Business consultantThe vast majority of problems within the workplace arise due to the lack of or inadequate communication between colleagues.All members of the organisation must develop their verbal and written skills to allow for ease of dialogue between the two parties. Regular dialogue is essential for the pooling together of ideas and suggestions that helps to minimise problems and help to achieve the company objectives.Employees must be able to interpret management edicts and be able to pass on these instructions to other staffs clearly and concisely in order to achieve peak performance.One opinion that might be made is that the companys impersonal uses of memos are substituting important meetings that would be held to discuss some of the key issues. By conducting regular meetings to open up a dialogue for discussion, it would help to eliminate any confusion that might have arisen because of their own interpretation of what is trying to be formed in the communiqu.By opening a dialogue between colleagues, it helps to make them feel a part of the team because they are being consulted and being offered to stress their opinions and grievances. During the meetings, it lets the individual know exactly what is being expected of them to do, with little chance for error. Once the individual knows the parameters in which they are expected to perform, and then the individual has some attainable guidelines on how to conduct him or herself around the workplace.Being made part of a team is one essential tool in the motivation of staffs. By including their opinions within any debate, it helps to raise that persons self-esteem. Once a person begins to become motivated, it often leads to greater job satisfaction.Job satisfaction is a combination of hard work and competence. Employees who reflect pride in their work are an infectious source of inspiration to others. This can be seen again in persons whom take personal pride and lead by example.Motiv ation is a key component to modern businesses. Staffs should take every opportunity to motivate others constantly. One way to encourage your staff is to let them know what is required of them by defining the days objectives.Use of praise and encouragement inspire maximum performance from an individual from a few choice words or phrases.Where an individual or team needs knock if they have made a mistake, remain calm and resolve the problem through constructive criticism. This is where the situation is given an explanation of what went wrong, gentle words to re-enforce the need that it does not re-occur, and gives further guidance on how it can be avoided in the future. It is imperative that if it is an individual involved, then take them to one side to discipline them. This way you are not undermining them and therefore their personal dignity is maintained.Another critical instruction is not to react to minor problems. Destructive and unwarranted criticism is harmful to morale and can easily sweep across a work force.It is also a good idea to be receptive to reasonable grievances that they might have and suggestions that they might make.Motivation encourages individuals and teams to continually achieve the companys goals through sustained peak performance.Part 3 Cleaning and the LawCleaning plays a fundamental part of food hygiene. It is pivotal in preventing contamination of both microbiological and chemical, but it also helps to make the indicator signs of pest infestation easier to spot.All cleaning comprises of four factors* Heat* Mechanical energy* chemic energy* Contact timeCleaning is usually a five stage process (although not exclusively).1) Pre-clean2) Main clean3) Rinse4) Disinfect5) Final mop6) DryingThe relative energy and time components of a cleaning programme can differ greatly. This is all dependants on the load of soil age, the chemical properties of the cleaning agent, and the surface to be cleaned. Staffs should receive clear concise inst ruction on how to correctly conduct the cleaning schedule.The chemicals used within this factory are as followsChemicalActionFatsolveSurfactant degreasing detergentBleachHypochlorite based disinfectantSparkleSurfactant degreasing detergent cutting foamAcidic de-scalerCaustic floor cleaner alkalic (NaOH) floor cleanerCaustic pearlsAlkaline (NaOH) fryer cleanerTego 2001Biocidal disinfectant/detergent combinationAll staffs that will be handling these products for use in hygiene must receive full training and monitored for competency and efficiency. All of these products must comply with the Health and Safety at Work Act 1974 to protect the employee whom is to be using these chemicals.This Act states specific legislation to includeThe Control of Substances Hazardous to Health Regs, 1994 (SI. 1994 No. 3246) (COSHH)These regulations require employers to assess the hazards and provide suitable controls. Implementation is by means of risk assessment. COSHH is concerned with chemicals that c an be classified as toxic, harmful, acerbic or irritant.All of the products used within the body of the factory are supplied with all COSHH safety sheets and are filed in the technical department. Each of these products is mentioned in the company HACCP plan to include the risk assessment of these products.Chemicals (Hazards, reading Packaging) Regs, 1993 (CHIP)Again, this states that all chemicals sold must be supplied with a COSHH safety sheet provided for the purchaser by the supplier. This must include detailed information about the product, its hazard classification under CHIP regulations. It is also prohibited to decant harmful chemicals into unmarked containers.Personal Protective Equipment (PPE) at work Regs, 1992These regulations enforce the employer to provide all necessary PPE required for a specific task so as to minimise the health and safety risks that the employees might be subjected to.There are several good reasons why effective cleaning is so important besides those mentioned earlier* It creates a good visual impression for both workers and visitors alike giving a sense that the business cares.* Helps to maximise the efficiency and costing of several types of products. For example, if a sauce is left to build up deposits, then it would restrict the diameter of the pipe work, making the motor have to run harder to pump product through, thus reducing the lifetime of that component. Its also helps to reduce wastege* Legal certificate of indebtednesss.It is that final point which needs further explaining.The food safety Act, 1990This law makes it an offence to contaminate food so that it would be unreasonable to expect it to be used for human consumption in its current state. It also states that a food proprietor and staffs must identify all steps that are critical to food safety and minimise those risks.This is further backed up by theFood Safety (GFH) Regs, 1995This states* Premises must be kept clean, designed to facilitate cleaning, and to protect against the accumulation of dirt.* Make it a requirement for all food business proprietors to identify any step in activities of the business which is critical to food safety, and to introduce sumptuary controls at those points identified.This law allows an enforcement officer to raise a non-conformance on the actual presence of dirt, and does not have to prove that that soilage poses a risk to healthThere is a clear legal and moral obligation that wherever there is a risk to food, a business proprietor must ensure that the working premises are kept clean so as to minimise the risks to public health. These responsibilities must be stressed to all employees not only in their induction period, but also sporadically throughout their employment.Part 4 PEST in relation to OEEDuring the course of this audit, an OEE analysis was conducted on one of the production lines (See OEE exercise workbook). The aim of GMP is to improve the manufacturing performance, and by using OEE calc ulations it is possible to gain a quantifiable index of performance. Using the precepts behind GMP it is possible to identify areas that could benefit from improvement so as to improve production performance.The identification of the seven wastes which are the non-value added and also the value added sections of a production period are vital. It is the main objective to reduce the first, and increase the latter.With regards to the production run that was studied several strategies can be entertained to help to minimise waste due to the above mentioned wastes. Firstly, fish cakes are products that produce only small amounts of waste due to the fact that defects can often be re-worked during the same production run. Defect cores can be removed from the line by operatives and then deposited back in the koppens former to be re-moulded into another(prenominal) cake.Reducing the throughput can often help reduce the rejects levels. Running at just a few strokes under the maximum for the li ne might make it more cost effective to reduce the throughput by a minimal amount in order to dramatically decrease the amount of reject product. By doing this the right first time figure could increase to raise overall production efficiency.If speed is the reverse factor, i.e. the faster the speed, the higher the defect rate, then just by reducing the stroke rate of the machine, the amount of over-processing required would be reduced. If however speed were not the decisive factor, then an investigation of the machines capabilities would have to be reviewed, and if it cannot be removed, then do you accept this defect level caused by the machine, or do you assess the possibility of purchasing a more efficient piece of kit?With regards to the machine that is in place, the Koppens former is approximately 10-15yrs old and forms cakes by using hydraulic cups and a forming plate. Over the years the maximum output of the machine has dropped by approximately 25% from the max of 40s/m to n ow 30s/m.Would it be better to buy a new piece of kit. Perhaps the purchasing an AEW forming machine? Unfortunately these are costly pieces of kit. be in the range of 250K. This is a large prohibiting factor in an SME of the size of the company in question, with their limited financial resources. In order to justify a capital expenditure of that magnitude, a significant order would have to be procured to allow for the required payback period to make it a cost effective purchase.It is almost chicken and egg scenario. With a new piece of machinery of this nature the potential for increased throughput of not only this line, but also of others would rise significantly, but monies or orders to cover payback periods would have to be secured before capital expenditure is considered.It is a difficult political climate with retail customers at present. more and more of the major multiples only issue contracts for periods of usually a year (although there has recently been a downward trend to decrease these to six monthly). So a guarantee off continued business is not certain, which prohibits the purchase of the new machinery.The small margins also affect the staff efficiency and retention (thus quality). Because margins are tight, only a small amount on the top of national minimum wage can be applied. This can limit not only the response to job advertisements, but also with staff retention and loyalty. With a higher staff turnover, the quality of staffs employed often reduces, thus affecting the throughputs and efficiencies of the lines.This interplay of factors is what has to be investigated further upon before resolutions can be found. Identification is just the first step in an overall improvement plan.Appendix 1Summary SheetsGMP Audit MaterialEnclosed in this booklet are copies of the audit checklists that you can use to audit your site against each element of GMP.You should aim to audit 2 elements of the standard each week and use the techniques discussed in wee k 1 on problem solvent to objectively assess each element of the standard.If you wish to discuss any elements in more detail then contact one of the tutors on the course who will be able to help you crystallize any problems or issues that you may have.IMPORTANTYou will need to copy the food safety and hygiene audit assessment form each week, as you will need to use this to summarize for each assignment.Using the Sample Assessment Forms for the 10 sections of Good Manufacturing Practice identify1. Areas of Strength and Weakness for the GMP sections for your own plant or operation, using the checklists provided.2. The causes of problems which are inherent with the areas of weakness3. The barriers and aids which will effect the improvement process4. Prioritise the actions needed to improve your Good Manufacturing Practice needs, using the assessment forms, which should be include within your weekly assignment.A grading system has been given on each checklist. You may use this grading system to help you to assess your factory, but feel free to condition this. If you do modify the system then you should explain, quite clearly, how the grading or scoring system is used.Key to the ABCD grading system for assessing the sections and elements of the GMP standardGrade A Excellent rack up 50 points. Grade A scored when there are no safety problems or issues. Requires no further action.Grade B Satisfactory Scores 30 points. Actionable within defined timescale as agreed at audit.Grade C Major Scores 10 points. Actionable within one working week.Grade D Critical Scores 0 points. A Grade D is automatically awarded when a critical safety issue is identified, and is actionable immediately.