Post on 18-Oct-2018
RESPONDING TO DEMAND FOR HIGHER QUALITY STANDARDS: TIME TO NAVIGATE THIRD PARTY
AUDITS Sacramento, Ca
July 30, 2014
Stephanie Lopez, AIB International
Adeline Druart, Vermont Creamery Robert Frie, Emmi-Roth USA
An Introduction to GFSI Audits
By Stephanie Lopez
Vice President, Food Safety Services Innovation AIB International
Types of Audits
Audit:
• Obtain evidence
• Evaluate it objectively
• Determine compliance
First party – internal audit
Second party – customer audits supplier
Third Party - independent
Third Party Audits
An independent assessment of your food safety programs
Benefits:
• Identify issues before they lead to illness or brand erosion
• Identify areas of opportunities for continuous improvement
• Supplier qualification
Global Food Safety Initiative
GFSI
• Launched in 2000
• Harmonizes global food safety standards
• Maintains a benchmarking document
• DOES NOT HAVE AN AUDIT SCHEME
• www.mygfsi.com
“Once certified, accepted everywhere”
GFSI
Scheme
Certification
Body
Accreditation
Body
Food
Company
BRC FSSC 22000 IFS SQF
ANSI UKAS
Others
Benchmarked Schemes
BRC: British Retail Consortium
FSSC 22000: Food Safety System Certification
IFS: International Featured Standards
SQF: Safe Quality Food
Others: specific to produce, meat, seafood, packaging, distribution
GFSI Audit Components Food safety policy
Food safety manual
Management responsibility / commitment
Management review
Resource management
Document control
Internal audit
Corrective action
Control of nonconformity
Product release
Purchasing
Supplier performance
Outsourcing
Complaint handling
Series incident management
Device calibration
HACCP
Food defense
Product labelling
Traceability
Sanitation
Pest control
Maintenance
Personal Hygiene
Training
Storage and transportation
Allergen control
GFSI Audit Components Food safety policy
Food safety manual
Management responsibility / commitment
Management review
Resource management
Document control
Internal audit
Corrective action
Control of nonconformity
Product release
Purchasing
Supplier performance
Outsourcing
Complaint handling
Serious incident management
Device calibration
HACCP
Food defense
Product labelling
Traceability
Sanitation
Pest control
Maintenance
Personal hygiene
Training
Storage and transportation
Allergen control
Management Responsibility/ Commitment
Senior Site Manager
• Involved in the audit
• Involved in key meetings
• Knowledgeable about food safety programs
• Responsible for food safety and failures
Management Review
Regular meetings
Report on status of the business
Report on objectives
Corrective actions for continuous improvement
Audit results Complaints HACCP Incidents Process deviations New science New legislation
Document Control
All policies, procedures, records
• Master list of documents
• Revision date
• Revision history
• Approval
• Procedure for rescinding obsolete documents
Document Name: Authored by: Document ID: Approved by: Effective Date: Page: # of ## Supersedes Date:
Internal Audit
Review of entire food safety system
Trained audit team
Auditors independent of area audited
Interviews and inspection
Document and record review
Conformance and non-conformance
Corrective and preventive action
Following our plan? Is it effective? Does it meet GFSI requirements?
Serious Incident Management
Crisis Management Plan • Recalls • Natural disasters • Regulatory investigations Includes: • Resources (legal, scientific) • Product disposition criteria • Facility disposition criteria
Preparing for a GFSI-scheme Audit
• One year to prepare
• Fully compliant 90 days before the audit
1. Study the standard
2. Gap assessment
3. Internal audit training
4. Pre-Assessment (or second gap assessment)
5. Audit
6. Close non-conformances
7. Certification
Case studies from other panelists….
Vermont Creamery path to BRC Adeline Druart, General Manager
Vermont Creamery ACS 2014
Why we decided to take on this project?
- Culture of continuous improvements
- Ensuring highest quality/consistency product
- Customers request
- Building safety
- Staff engagement
Which certification to chose?
- Be part of the GFSI program
- Fit with current QC programs
- Be in line with current operations and business practices
- Chose certification body that is recognized by your customers
Our QC system prior BRC:
- HACCP plan
- Recall/traceability plan
- Employee training/GMP program
- Raw material/Product/FG testing protocols
- Culture of Quality and rigor
3rd Party Decision Chart:
1. Search GFSI scheme
2. Estimate “best fit” which existing QC program
3. Order the Standards + Interpretation guideline and study it
4. Start your to do list
5. Create timeline and budget
Investing in BRC certification:
- Administrative tasks: procedure writing ….
- Training staff – meetings – follow through
- Building structural changes
- Equipment purchase/upgrade
- Pre-audit: practice before the game
QC supervisor/ manager salary
Production TL/Supervisor training time – staff meeting time
Walls/ceiling renovation – changing rooms reno – new drains - …..
New Lab equipment – floor testing equipment
Pre-audit: $4,000-$6,000
Vermont Creamery path to BRC:
Selection GFSI scheme
Select certification
auditor
Pre-audit preparation
Pre-audit
BRC 1st accreditation
audit – GRADE B
BRC 2nd annual audit –
GRADE B
BRC 3rd annual audit –
GRADE A
2013
2012
Oct 2011
Aug 2010
March 2010
Jan 2010
Nov 2009
BRC Standards:
1. Senior Management
2. Food Safety
3. Quality System
4. Site Standards
5. Product control
6. Process Control
7 Personnel
BRC Audit path:
1. Senior Management Commitment
• Commitment to Quality in writing
• Annual customer business review notes
• Manager meetings notes
• Weekly QC meeting
Vermont Creamery BRC Implementation:
Vermont Creamery BRC Implementation:
2. Food Safety Plan – HACCP:
• HACCP team
• Product Profiles
• HACCP flow charts
• Hazard analysis – decision chart
• HACCP deviation report
• Record retention policy
• Raw material hazard analysis
Vermont Creamery BRC Implementation:
3. Food Safety and Quality Management System
• Quality document
• Quality manual
• Internal GMP audit
• Supplier approval program
• Inbound-outbound truck
• Lab SOPs, COA
• Ingredients, Products
and packaging program
• Make sheets
• Corrective/Prevention Action Plan
• Hold and Release procedure
• Mock recall
• Customer feedback records
• Business continuity Plan
• Incident Management team
Vermont Creamery BRC Implementation:
4. Site Standard • Local Hazard Identification • Food Defense Plan • Process Flow map • Security system • Raw product in fully enclosed
dairy pipes • Walls and physical separation • Drain maps • Glass and Brittle Plastic
checklist • Water testing + mapping
• Equipment Hazard analysis • Preventive Maintenance
Program – work orders • Non-Food grade
chemicals/lubricants storage policy
• Sharp tool policy • Wood policy • Metal detector • Pest control Program • Temperature Alert System
Vermont Creamery BRC Implementation:
5. Product Control • Shelf life evaluation • Allergen program, ingredients spects, supplier approval program • Cross Contamination policy • Packaging verification • Finished Good testing program • Lab data recording program • Calibration program
Vermont Creamery BRC Implementation:
6. Process Control • Make sheet • Chart records • State calibration: HTST, Vat pasteurizer • FG verification program • In-line weight verification program • Calibration schedule
Vermont Creamery BRC Implementation:
7. Personnel • Employee training program • Training records + quizz • Hand washing procedure • GMP training • Visitors program • Unifirst - workwear program • Gloves program
Global Food Safety Initiative (GFSI)
Food Safety System Certification 22000 (FSSC 22000)
Robert Frie
Plant Manager Emmi Roth USA
About Emmi Roth USA
• Emmi - International Company HQ in Switzerland
• Emmi Roth USA – Originally founded in 1991 in
Monroe, WI as Roth Kase
– Purchased by Emmi 2011
– Mfg Specialty Cheeses and Fresh Dairy products
– 4 manufacturing facilities in the US (California, Wisconsin, and New York)
– Approximately 400 employees
The Journey Begins……… • Management’s commitment
– Absolutely begins here!
– Non-Negotiable
– Must be involved & participate
– Must talk the talk & walk the walk
– Must act on the need for Improvement
– Must LEAD the change in culture
• Lead by example – your Brand and Company are worth it!
Decisions to be made
• Which Scheme to chose – BRC, SQF, FSSC 22000, etc.
• Which accredited body to chose – AIB, SGS, Silliker, etc
– Is there training available?
– Costs
• Time line – Pre Assessment
– Employee training
– Certification
– Resources
Which Standard should we implement?
• Research the standards to see which one fits your company’s needs.
– Certification timeline
– Training needed / available
– Costs
– Labor/Resources
– Customer base acceptance
– References
2014 Aug Sept Oct Nov Dec 2015 Jan Feb Mar Apr May June July Aug
SepS
Kick Off
EVENT
Form
Food
Safety
Team
GFSI
scheme
and CB
Planning
Gap
Analysis
Create or
Review and
strengthen
your
HACCP
Education
and
training on
the
standard
Certification Timeline
Create
Food
Safety
Policy
Certification
Audit!!
CELEBRATE
Internal
Audits
w/CA
Food Safety Team routinely meets – continuously improving
Training of
FST and
Internal
Auditors
Education
and
training on
the
standard
Internal
Audits
w/CA
Internal
Audits
w/CA
Internal
Audits
Begin
w/CA
Re-assess
Gap
Analysis
Pre-
Assessment
Audit
(w/CA)
Continuously
Developing
• Lack of Management support – It’s not a “PROGRAM” with a start and stop – Not leading the transition in culture change
• Lack of resources – Not enough people man hours – Too many hats being worn
• Implementation timeline too aggressive – Corrective actions vs band aids – Allow yourself time to build a structured food safety system
• Understanding the standard – “Shalls” – Showing objective evidence (young system vs established)
• GAP analysis was poorly done – Allow enough time to perform
Challenges with GFSI Audits being “recognized”
• 3rd Party Audits – Silliker
– Perry Johnson
– Cook n Thurber
• Customer Audits – Walmart
– Military
– Schreiber
• State / Federal Audits
• “other” ISO Audits
Food Safety is Transparent!
• Avoiding illnesses and deaths
• Sharing information and successes
– Synergies
• Safeguarding the supply chain
• Brand protection
• Continued success of your company
• Saving resources and money
Message to take home….
Benefits of Certification under GFSI
• Supplier Qualification
• Reduced 2nd and 3rd Party Audits
• Improved Food Safety System
– Focus on food safety
– Systems approach
Retailers who recognize GFSI benchmarked schemes in their supply chain
• Burger King
• Campbells
• Cargill
• ConAgra Foods
• Danone
• HEB
• Hormel
• ICA
• Kraft Foods • Kroger • Loblaw • Maple Leaf • McCain • McDonalds • Pick-n-Pay • Publix • Raley’s
• Raley’s
• Shop Riter
• Sodexo
• Coca-Cola
• Tyson
• US Foods
• Walmart
• Wegmans
Questions ?
Stephanie Lopez Vice President, Food Safety Services Innovation AIB International SLOPEZ@aibonline.org
Adeline Druart General Manager Vermont Creamery adruart@vermontcreamery.com
Robert Frie Plant Manager Emmi Roth USA Robert.frie@eemirothusa.com