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Auditor Calibration The webinar will start shortly
Auditor Calibration
The webinar will start shortly
Auditor Calibration Webinar(October 2012)
David Brackston &John Figgins
Content
• Expectations of the audit process• Review of key sections of the audit report
summary• Non-conformity reporting• Review of the detailed audit report• Next steps• Questions
Issue 6 Audit Format
Issue 6 introduced some behavioural changes in terms of the format/style of the audit:
• 50% time in factory
• Opening of equipment during the audit to confirm cleanliness
• Observation of changeovers and line sign off
• Inclusion of traceability exercise allowing a vertical audit
1.Audit Summary
Company name The Bakers Oven BRC site code 1768780
Site name The Bakers Oven
Scope of audit The production of bread rolls and buns.
Exclusions from scope None
Audit finish date 2012-07-14
2. Results
Audit result Certificated Audit grade B+ Audit type Unannounced – option 2
Audit frequency 12 months Re-audit due date 2013-07-14
Previous audit grade B Previous audit date 2011-07-10
Number of non-conformities
Fundamental 0Critical 0Major 1Minor 2
3.Company Details
Address 1 Pudding Lane London EC21 5XY
Country UK Telephone 0116 2345678
Commercial representative name
Ed Baker Email [email protected]
Audit ReportGlobal Standard for Food Safety Issue 6: July 2011
Soft cheese (e.g. brie) produced using pasteurised milk. Whey by-product packed into 25kg drums.
Scope Example (I)
Production and distribution of bread rolls and prepared sandwiches for catering and wholesale.
Fully baked bread rolls (white, wholemeal and granary varieties) and ready to eat sandwiches.
Milk receipt, design and development, production, ripening, packaging and shipping of cheese. Production and shipping of milk by-products.
XX
Scope Example (II)
The preparation of ready meals containing vegetables, meats and sauces employing: Brat pan cooking/frying, kettles blending and cooking, continuous tray ovens and chargrills, blast chilling and hand packing for chilled and frozen storage distribution.
Comminuted poultry products, marinated and/or breaded. Products are flash fried and chilled or frozen. Products are ready to eat or reheat.
The preparation of ready meals containing vegetables, meats and sauces. Ingredients are fully cooked and packed chilled or frozen.
X
Exclusions from Scope (I)
• Issue 6 restricts permitted exclusions to scope to ensure:o Clear management commitmento Consistent standards across the siteo Protection of the CB and BRC in the event of
an incident
Exclusions from Scope
The exclusion of products produced at a site will only be acceptable where the excluded products can be clearly differentiated from products within scope and
make up a minority of the products produced at the site and: • the products are produced in a separate area of the factory or • the products are produced on different production equipment, e.g. products
packed in glass jars in a cannery.
The Processing of canned tuna in oil & brine
Exclusions: canned yellow fin tuna
Products not specifically distinguishable
XX
Scope Wording
F033: Guideline for defining wording of scope
Finished product safety rationale
Ambient stable, short shelf life (<7 days), baked (minimum core temperature of 94oC),Preservative (calcium propionate > 1000ppm)
Product Safety Rationale
The product safety rationale is designed to summarise the key characteristics of the product and production processes that make the final
product microbiologically safe for consumption throughout its shelf life.
Further guidelines will be published in due course
Assignment of High Care/Risk
• Issue 6 expanded the requirements for High Risk and High Care:o A guideline is availableo The site must be correctly assessed and
assignedo It is important that the high risk/high care
status is accurately recorded on the audit report
Non-Conformity RecordsMinor
No. Requirement ref.
Details of non-conformity Corrective action taken Root cause analysis and proposed
action plan
Evidence provided document, photograph, visit/other
Date reviewed
Reviewed by
2 3.4.1 Internal audit of supplier management systems scheduled for January had not been carried out.
Audit now completed as have audits scheduled for October, November and December.
Root Cause: Procedures didn’t recognize the need for deputies and therefore no alternative staff had the appropriate qualifications/ training when key staff were on long term sickness.
Proposed Action: Internal audit procedures updated to incorporate deputies. The size of the internal audit team will be increased to include sufficient members. These staff will be trained, as appropriate, for the systems to be audited.
Copy of audit reports
M Oliver
06/08/ 2012
2.10.1 Major Incomplete CCP monitoring – the non-ferrous test piece is not used
4.10.3.5 Major
A non-ferrous test piece is not routinely used for checking the metal detectors. The HACCP states that metal detection is a CCP and critical limits have been set for ferrous, stainless steel and non-ferrous test pieces. Test procedure (reference MD1-11) states these must be used for each metal detector check during production.
X
Example
Non-Conformity RecordsMinor
No. Requirement ref.
Details of non-conformity Corrective action taken Root cause analysis and proposed
action plan
Evidence provided document, photograph, visit/other
Date reviewed
Reviewed by
2 3.4.1 Internal audit of supplier management systems scheduled for January had not been carried out.
Audit now completed as have audits scheduled for October, November and December.
Root Cause: Procedures didn’t recognize the need for deputies and therefore no alternative staff had the appropriate qualifications/ training when key staff were on long term sickness.
Proposed Action: Internal audit procedures updated to incorporate deputies. The size of the internal audit team will be increased to include sufficient members. These staff will be trained, as appropriate, for the systems to be audited.
Copy of audit reports
M Oliver
06/08/ 2012
Non-Conformity RecordsMinor
No. Requirement ref.
Details of non-conformity Corrective action taken Root cause analysis and proposed
action plan
Evidence provided document, photograph, visit/other
Date reviewed
Reviewed by
2 3.4.1 Internal audit of supplier management systems scheduled for January had not been carried out.
Audit now completed as have audits scheduled for October, November and December.
Root Cause: Procedures didn’t recognize the need for deputies and therefore no alternative staff had the appropriate qualifications/ training when key staff were on long term sickness.
Proposed Action: Internal audit procedures updated to incorporate deputies. The size of the internal audit team will be increased to include sufficient members. These staff will be trained, as appropriate, for the systems to be audited.
Copy of audit reports
M Oliver
06/08/ 2012
Summary Sections (II)
HACCP Team led by Ian Greaves the Technical Manager who is trained (Campden 2007) and experienced with HACCP and included representatives from engineering, production, development and hygiene. HACCP based on the principles of Codex Alimentarius initiated in 2004, last updates (now version 4) 17/11/11 and 28/01/12 with pre-requisites identified, verified and signed off by HACCP team. Customers’ codes of practice have been referred to.
Product description: Fresh products, baked on site with shelf life of 3-12 days stored ambient in plastic packaging.
Allergens present in recipes are labelled, and include wheat, milk, milk powder, soya, eggs and sesame seeds.
Recipe exceptions within product modules were identified and risks associated identified, e.g. the use of sesame seeds on burger buns. Gluten free and organic products also produced.
3 generic parts covering bread, rolls and speciality rolls, although potential recipe variations between products within a generic group were identified. Process steps: Receipt, inspection/sieving, storage, mixing, proving, baking, cooling, slicing, packing, metal detection, storage and despatch.
Significant hazards have been identified as foreign bodies specifically metal. The team have used a 4 step decision tree
CCPs (including quality considerations) = ingredient sieving (1.5-10mm), baking core temperature (min 94C), cooling temperature (max 25 C), metal detection (2mm Fe, 2.5mm Non Fe, 3.5mm SS). Critical limits had been agreed and signed off by team. Bake and cooling temperatures were based on published data for microbial growth (Campden). Sieve size and MD sensitivities based on industry best practice.
CCPs are monitored and recorded every batch. Metal detectors checked hourly, sieve integrity checked start and end of shift. Non-conforming product usually disposed of following sign off by Senior Manager.
2 The Food Safety Plan – HACCPFUNDAMENTAL Statement of Intent
The company shall have a fully implemented and effective food safety plan based on Codex Alimentarius HACCP principles. Y
Summary Sections (III)
Ingredients are sieved as previously detailed.
All products metal detected post packing.
Metal detectors tested hourly 2mm ferrous, 2.5mm Non-ferrous, 3.5mm stainless steel. Tests include single products and consecutive products and allow detected product to be rejected into a locked bin with belt stop, audible and visual alarm.
No historical failed test seen in documented checks, however metal detectors on both roll plants failed to reject ferrous and non-ferrous test pieces during witnessed test. Refer major non-conformity number 1.
Maintenance of metal detectors is subcontracted.
4.10 Foreign body detection and removal equipment
4.10 Foreign body detection and removal equipmentForeign body detection includes two CCPs - ingredient sieving & metal detection.
All dry ingredients are sieved (1.5 – 10mm depending on the ingredient). Sieve integrity is checked at the start and end of shift.
All products metal detected post packing.
Metal detectors are tested hourly using 2mm ferrous, 2.5mm Non-ferrous, 3.5mm stainless steel test pieces. Tests include single products and consecutive products and allow detected product to be rejected into a locked bin with belt stop, audible and visual alarm.
No historical failed tests were seen in documented checks (line 1 records for June & July 2012 and line 2 May & June 2012), however metal detectors on both roll plants failed to reject ferrous and non-ferrous test pieces during the witnessed test. Refer to major non-conformity number 1.
Maintenance of metal detectors is subcontracted.
Conclusions• Audit reports form an important part of the audit/certification process
• The audit report isn’t intended to be a time consuming exercise but it is important that auditors record:o Sufficient informationo Quality information
• Audit reports need to completed in a consistent way by all auditors
• Supporting documents are available on the BRC websites (brcglobalstandards.com or myBRC)o Recent guidelineso Model reportso Auditors’ checklists
• An audit report exercise is being developed by BRC and will be circulated shortly
Next Steps
• Cascade to auditors
• Calibrate auditors
• Webinar recorded and available
• Follow up exercise
• Publication of Q & As
