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Preparing for a

Successful FSHC Audit


(FSHC =
Food Safety Health Check)
FSHC
► What is a Food Safety Health Check (FSHC)
audit?
 This audit is an audit of Good Manufacturing
Practices (GMP’s), Product Integrity (PI), and
the presence of a HACCP (Hazard Analysis
Critical Control Point) program.
 Previously Silliker (Silliker is the name of the
company that performed facility audits) audited
our GMP’s and PI. No formalized HACCP
program was present at AB at that time.
FSHC
 The Food Safety Health Check Audit is scheduled
annually over a week.
 Zone Quality will conduct the audit. He/she is escorted
by Area Owners (Managers/Supervisors) who will also
participate in corrective actions
What is HACCP?
► HACCP (Hazard Analysis Critical Control Point) is a
FOOD SAFETY program.
► Ensuring the safety of our products is critical.
Protecting our consumers from injury and illness is
our #1 priority, even more than Quality.
 A beer with high TPO doesn’t kill someone, a beer with
a glass inclusion could cause serious injury or death.
 Companies that have had documented safety issues
and/or recalls lost millions and in some cases, never
recovered to their pre-incident sales/earnings.
What is HACCP
► Components of a HACCP program are:
 Up-to-date HACCP Binder, including Prerequisite
Programs and Forms (reviewed min 1x/yr)
 HACCP Forms, including emphasis on Hazard
Analysis
 Active HACCP Team
 HACCP Training (e-learning for all employees)
 Identification of Critical Control Points, training
around testing and reaction
GMP’s
Employee Practices
Earplugs
► Earplugs must be worn
with the cords on.

NO
Earplugs
► Assure you dispose of used
earplugs properly, and the
wrapper they came in.
► Earplugs do not belong
with recycled material.
Hairnets/Hats
► Hairnets or Clean Hats
must be worn on the
filler platform, or near
empty can conveyors,
( in any location where
there is a chance of
drop in
contamination.)
Hairnets/Hats
► Hairmust be
appropriately tied to
prevent injury, and
then covered
appropriately.

Correct
Beard Nets
► FacialHair must be
covered by a beard
net.
► A trimmed neat
mustache does not
require a beard net.

Correct
Dress Code
► Sleeveless shirts/ tops
are not allowed.
(Underarm hair)
► Socks are required
NO
► Shorts are not allowed.
(Leg Hair, potential
injury.)
 Shorts are allowed in
some facilities in
restricted areas. Check
with your EHS dept.
Jewelry
► The FDA states to remove
all unsecured jewelry and
other objects that might
fall into food, equipment
or containers, and NO
removing hand jewelry
that cannot be adequately
sanitized.
 Please consult your facility’s
Jewelry Policy
► If hand jewelry cannot be
removed, it must be
covered with a sanitary
material
Employee Clothing
► Employee clothing
must be clean.
► Clothing must not have NO
strings/loose areas
that could get caught
in machines.
NO
Employee Clothing
► No loose items shall be
present in employee
pockets (pens, pencils,
tools, etc) that could
fall into product.

NO
Smoking
► Smoking is allowed in
designated areas only
► Cigarettes cannot be
stored in your shirt
pocket unless its
buttons are closed
► Smokeless tobacco is NO
also prohibited
Smoking
► Cigarette butts in the
production area or
trash cans or on the
NO
ground outside are a
violation.

NO
Eating
► Thereis to be no
eating in the work
area.
Eating/Gum Chewing
► No gum chewing,
eating of hard
candies, nor cough
drops, nor mints,
nor anything similar
is allowed in the
labs, or on the NO
production floor.
Drinking – Water Only
► There is to be no
NO
drinking of beverages
other than water in a
clear container in the
work area.
 Several facilities
regulate water
consumption differently
in production areas.
Consult your HACCP
team or Quality
Manager.
Drinking – Water Only
► Do not discard coffee
cups in the work area.
Use trash cans outside
the building or in a
break room. NO
► If you have a coffee
mug, it cannot be in
the production area.
Evidence of Eating
► It is not allowed to
NO
discard wrappers,
peelings, or any food
related container, etc.
in any trash can in any
production area or lab.

NO
NO
Eating
► It is not allowed to
store any lunchbox or
even an empty
tupperware/bowl/sack
(with food residue) in
any production area.
► Cabinets on the line,
lockers, lab drawers,
and totes are not food
storage places. Correct
Personal Storage
► Any Jacket or Backpack
or other personal item
must be kept in the
designated storage
area, zipped.

NO FOOD or FOOD
CONTAINERS
Personal Storage
► Itis not allowable to
keep food loose in the
tote. Utilize the
refrigerators near the
cafeteria or keep in
your car.

NO
Personal Storage
► Unapproved Chemicals
cannot be kept in the
Production area.
► If you have personal
lotion, creams,
medicine, etc., it
should be kept in your
zipped backpack.

Approved Lotion
Hoses
► Hoses must be stored
appropriately, in a
holder.

NO

NO
Brooms/Mops
► Brooms and Mops
must be stored off the
floor, in designated NO
areas, and cannot
have WOOD handles in
the production area
(where it is wet)
 Wood handles that are NO
kept clean and made of
non-porous wood are
acceptable.
Everything should be in Its Place
► Part of 5S is having a
place for everything
and everything should
be in its place.
 Empty Sparkletts
bottles not be sitting on
this bumper in
production area.

NO
Pasteurizer Doors/Bars
► Pasteurizer doors must
be kept closed.
► Pasteurizer bars for
product changes must
be stored in the
designated place.

Correct
Restroom
► Restroom doors must
be kept closed at all
times.

NO – Keep Closed
Restroom
► Signs that say
“Employees must wash
hands before returning
to work” must be
present in all
restrooms
► Employees must WASH
their hands with soap
and hot water.
Restroom
► Unsanitary conditions,
or shortage of supplies
should be reported
when identified, for
immediate correction.
► Call your local janitorial
service providor or the
Shift Manager
Touching Materials
► No employee shall
stick their fingers in
cans.
► No employee shall
touch the undersides
of lids.
NO
Touching Materials
► No employee shall
touch crown liner.
► No employee shall
touch the bottle finish.
► Employees must have
clean hands when
handling materials.

NO
Return of Material to Warehouse
► Crowns must be put
back in a plastic bag, it
must be sealed, and
NO
then placed in a
cardboard box. It is
ok to fold the
cardboard box, but the
bag MUST be sealed.

Twist bag inside to seal then fold box


= Correct
Return of Material to Warehouse
► Open sleeves of lids
must be closed.
► All other material
should be closed, and
protected with a piece
of cardboard.
 Do not use slip sheets
for covering material.

Correct
Misuse of AB Materials
► No Production can
shall be used for
storage of pencils,
NO
pens, chemicals, etc.
► No lids shall be used
as coasters or shims.
► No trays shall be used
as blotters, etc.
► Packaging material is
Correct
for one use only.
Test can used
to collect glue
drippings.
Misuse of AB Pallets
► AB product pallets are
NEVER to be used for
anything other than
finished product.
► Not motors, not
chemicals, not grease,
not lube, not
storeroom parts, not
anything but finished
beer/kegs. NO
Misuse of Slip Sheets
► Slipsheets between
can layers are the
property of the can NO
manufactures
► Slipsheets must not be
used as covers or for
any other purpose. All
must be returned to
the can plants
Misuse of Slip Sheets
► Slipsheets between
incoming glass are not
the property of the LA
Brewery.
► They are not to be
used for any other
purpose. All must be
returned to the glass
plant.
NO
Chemicals/Labeling
Chemical Labeling
► Chemicals, and
specifically secondary
containers, must be
clearly labeled and
appropriately labeled
Chemical Storage

► Chemicals must be stored appropriately


Buckets
► Buckets or other
similar vessels must be
labeled with their use.
► For example, a bucket
that has been used for
grease should not then
be used for production
inputs.

Properly Labeled
Buckets
Buckets
► Examples of incorrect
bucket practices.
NO

NO

NO
What is wrong with this picture?
Facility Cleanliness &
Repair
Foul Odors/Slime
► Odors from slime,
odors coming from
drains, odors from any
other source, must be
addressed
Slime or Mold on Floor
► Slime or mold on the
floor are actionable
items. NO
► Both can also be slip
and fall issues, in
addition to sanitation
concerns.
NO
Insects/Birds/Pests
► Know you local pest
control provider
► If you need service, call
you QA department
► Or send an email to them
listing:
 What the infestation is
 Where it is
 Your name and contact
Pest Stations
► Pest stations must be
in the proper location,
and oriented properly.
► (Mice would run along
the wall, so the holes
should not be up
against the wall.)
 Note: Insure a station is
on each side of the
door leading to exterior.
Rusting and Peeling Paint
► Rust and Peeling Paint
are violations.
► Even if this cannot be
corrected immediately,
NO
Rust and peeling paint
should be sanded off
to prevent drop in
contamination.
► At minimum, report
the area or equipment, NO
for painting.
Peeling Paint - Illustrations

NO
Cabinets

NO
NO

► No storage on top of cabinets, electrical boxes,


etc.
Broom Storage
► Brooms should be
stored appropriately.
Correct –
Bristles down

Incorrect –
Bristles up
Cabinets

NO

► Cabinets
should be 5-S ready at all times.
► Non-compliance will be noted on the FSHC audit.
Guards
► Guards that prevent
drop in contamination
must be in place and
in good condition.

Correct
Drip Pans
► Drip pans MUST be in
place for any motor
that is above product.
► These drip pans are to
be monitored for
leaking oil.

Drip Pan
Needed
Production Materials
► Production materials
are never stored
directly on a floor.
► They must be kept on
a pallet or table.

NO
No Storage along the Walls
► Is the storage of
materials and
equipment a minimum
of 18 inches from
walls?

Correct
Motors
► Motors shall be
cleaned of dust.
► Motors should be free
of oil and rust.
Fans
► Fansmust be kept
clean of dust build up.
NO

NO
Soap
► Soap should not get
onto the sides or the
top of the packages.

Correct
Soap
► Drains on the floor or
in pans should remain
clear, to remove soap
and wastewater
effectively.
Test Case Storage
► Test cases must be
stored appropriately
(not on the floor), and
must be protected
during line cleaning.

Correct
Shrouding
► Shrouding must be
present where
conveyors cross over
product, to prevent
drop in (or drop on)
contamination.

Correct
Shrouds
► Shrouds must be kept
in good repair.
Shrouding cleanliness
► Dustor other material
must not build up on
shrouds.

NO
Cold Room
► The cold room door
requires special care to
prevent mold build up.
► This is a picture of
mold build up on a
cold room door due to
the condensation
within. Appropriate
cleaning frequencies
can address these
issues. NO - Mold
Dock Doors

► Dock doors must be free of damage.


No Damage =
Correct

NO
Ceiling Staining

NO

► Ceiling (or pipe) staining is an indication of past


drop in contamination potential.
► It will be recorded during the audit.
Temporary Fixes
► Is facility free of
temporary repairs
(string, tape,
cardboard, etc.)?
► Temporary fixes are
often safety issues.
They are almost
always product
integrity issues.

NO
Keg Labels
► The keg line must
monitor product for
the effectiveness of
removing foreign
labels.

NO
Conveyors
► If cardboard dust
builds up on a
conveyor, it should be
cleaned. It can
actually start on fire.

NO
Damage
► Damage to walls,
pillars, etc must be
fixed as soon as
possible.
► If needed, bumpers or
wainscoting should be
installed.

NO
Blowers
► Blowers have a large
potential for dust
accumulation.
► These areas should be
a focus.

NO Dust
build up!
Wash Offs
► Wash offs are not used
in most cases, due to a
company policy
mandating the
conservation of water.
► If a wash off is in use,
corrective action would
be needed if nozzles
are plugged.
Warehouse - Leaks
► Leaks over finished
product in the
warehouse are
especially critical and
must be corrected
immediately.

Potential Condensate leakage


from Swamp Coolers
Warehouse - Trailers
► Trailersfor outgoing
(and incoming)
material must not be
damaged
NO
Warehouse – Beer Spillage

NO

► Beer spillage is critical in the warehouse, as it can


attract pests. Spillage cannot be rinsed away as
easy as in a production area.
Lights
► Alllighting fixtures
must have explosion
proof coverings in all
production areas.
Summary
► The FSHC Audit is an audit of Good Manufacturing
Practices (GMP’s), Product Integrity (PI), and the
presence of a HACCP (Hazard Analysis Critical
Control Point program).
► Involvement from everyone in the facility to
sustain the efforts of 5S and sanitation are critical
for long term success.
► Maintain your facility properly so that you are
ready for a FSHC Audit every day.
► Know your HACCP CCP’s, how to test, and how to
react to a failure.

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