Sample of The Assured FSMS Certification Workbook

ISO 22000 Food Safety Management System Implementation Workbook
This comprehensive Food Safety Management System Certification package contains EVERYTHING you will need to achieve ISO 22000 Certification. It has taken me nearly a year to put this package together, but I wanted to make sure that I came up with a product that was: Straight forward to implement. Available for instant download Able to eliminate the need to buy any other package or documentation Affordable for everyone I have written this workbook to assist in the implementation of your food safety management system. The workbook is divided into 8 steps that are designed to assist you in implementing your food safety management system effectively: Step One: Introduction to ISO 22000 Step Two: Senior Management Implementation Step Three: Training Step Four: Project 22000 Step Five: Food Safety Quality Management System Step Six: Internal Auditing Training & Checklists Step Seven: Review and Updating Step Eight: Final Steps to ISO 22000 Certification
For more information e-mail me at tony@22000foodsafety.com
www.22000foodsafety.com

Step Two: Senior Management Implementation An 11 step Senior Management Implementation checklist is provided that establishes your Food Safety Management System fundamentals including Food Safety Policies and Objectives. The checklist guides Senior Management: in planning the establishment of the FSMS in providing adequate support to establish the FSMS in ensuring there is adequate infrastructure and work environment in allocating responsibility and authority This stage requires the Senior Management to meet and establish the foundations for the Food Safety Management System: Formulating a checklist of Customer, Regulatory, Statutory and other relevant Food Safety requirements Decide which Food Safety requirements the company should address and develop relevant policies. Based on the Food Safety Policy Management Policies establish Food Safety Objectives Define the scope and boundaries of the FSMS Plan the establishment of the FSMS using the project planner Provide adequate support to establish the FSMS Ensure there is adequate infrastructure and work environment Allocate responsibility and authority Assess, plan and establish appropriate internal and external communication (including the food chain) channels
A meeting should now be co-ordinated involving all the Senior Management Team.

Senior Management FSMS Implementation Meeting Date Time Venue Agenda 1. Formulating a checklist of Customer, Regulatory, Statutory and other relevant Food Safety requirements 2. Decide which Food Safety requirements the company should address and develop relevant policies. 3. Based on the Food Safety Policy Management Policies establish Food Safety Objectives 4. Define the scope and boundaries of the FSMS 5. Plan the establishment of the FSMS using the project planner 6. Provide adequate support to establish the FSMS 7. Ensure there is adequate infrastructure and work environment 8. Allocate responsibility and authority 9. Assess, plan and establish appropriate internal and external communication (including the food chain) channels Attendees:
Senior Management Team Job Title Managing Director Site Director Operations Manager Technical Manager Planning Manager Distribution Manager Maintenance Manager Finance Manager Human Resources Manager Name Role in Team Chairman Deputy Chair Operations Reporting Food Safety and Quality Reporting Management Representative Planning and Capacity Reporting Distribution Reporting Services and Engineering Provision Financial Reporting Resource reporting

Senior Management Establish the Project Plan Using the Excel Project Planner Senior Management adapt the template supplied with the system to establish a Project Plan.
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Senior Management Establish Food Safety Responsibility & Authority Levels
Process Purchases
Responsible Persons Purchasing Manager
Activity Purchase ingredients from approved and certified sources Ensure purchase orders comply with applicable specifications Ensure adequate information on supply application form Ensure suppliers adhere to supply handling practices Perform suppliers audit or review supply status where necessary Compare PO and DO or check contracts as per Suppliers Specifications criteria (if applicable) Check receiving temperature, pest infestations, quality, packing conditions and truck hygiene. Observe unloading practices Handle incoming goods as per documented procedures Ensure Good Storage Practices and FIFO rotation principles Follow safe food preparation and handling practices Check environmental hygiene and safety Check equipment process performance and maintenance Check water quality and safety Check raw materials identification and traceability Maintain product recipes and characteristics Do not modify recipes prior to approval from top management Follow safe food handling practices Ensure Good Manufacturing Practices are adhered to Follow cleaning and sanitation standards and procedures Follow the handling standards of raw and processed foods Follow safe food holding procedures Hold foods outside the range of danger zone Follow safe food filling procedures into primary packaging Follow safe capping procedures Ensure food in primary packaging are hygienically located Ensure coding for traceability is performed to procedures Follow secondary packaging procedures to protect products
Technical Manager
Receiving and warehousing
QA/QC & Store Executives
Preparation of Ingredients
QA/QC, Production Manager & Production Executive QC/QC, Production Manager, Supervisor & Operators
Production
Holding and Filling of Processed Food
Production Supervisor & Operators Production Supervisor & Operators
Capping, coding and packing
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Step Three: ISO 22000 Training A significant part of the implementation process is training. Job Descriptions should be available for all staff and they should be briefed and aware of their food safety responsibilities. A training matrix and plans should be drawn up for all staff and the relevant training given based on responsibility and authority.
We have provided a Staff Training Matrix Template in Microsoft Excel Format. For each employee and individual training record should be completed. QMR 002 Training Record is provided in the documentation pack as a template:
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QMR 002 Training Record
Basic ISO 22000 Training should be given to all staff: Introduction to ISO 22000 Training: Understanding ISO 22000 The Food Safety Team should receive extra training: Food Safety Team: ISO 22000 Implementation Guide ISO 22000 Document Requirement Guide Prerequisite Training Codex GMP Training HACCP Training
Remember all food handlers should receive Basic Food Hygiene Training
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Training: Introduction to ISO 22000 This 45 minute Introduction to ISO 22000 supplied PowerPoint presentation can be used to introduce all staff to the ISO 22000 standard and explain how to start the process of implementing an ISO 22000 compliant Food Safety Management System.
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Training: Understanding ISO 22000 The one hour Understanding ISO 22000 interactive PowerPoint training guide supplied can be used to aid your staff in understanding the ISO 22000:2005 standard. It includes: The key elements to ensuring food safety An explanation of prerequisite programmes The principles of HACCP ISO 22000 definitions The documents required to meet the standard And much more...
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Training: Food Safety Team: ISO 22000 Implementation Guide The Food Safety Team: ISO 22000 Implementation Guide PowerPoint presentation supplied with the systemexplains to the Food Safety Team exactly how to implement an ISO 22000 compliant Food Safety Management System.
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Training: ISO 22000 Document Requirement Guide The ISO 22000 Document Requirement Guide PowerPoint presentation supplied explains to the Food Safety Team the documentation required in an ISO 22000 compliant Food Safety Management System.
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Prerequisite Training The Prerequisite Programme PowerPoint presentation supplied explains the part that prerequisites play in an ISO 22000 compliant Food Safety Management System.
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Codex GMP Training This interactive PowerPoint presentation explains CODEX & Good Manufacturing Practice Guidelines. The CODEX Principles lay a firm foundation for ensuring food hygiene. The controls described are internationally recognized as essential to ensure the safety and suitability of food for consumption.
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HACCP Training An interactive and illustrated PowerPoint HACCP training presentation is supplied to train your food safety team in the preliminary steps to a Hazard analysis, the principles of HACCP and how to utilise the HACCP calculator in implementing your HACCP system.
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HACCP Training An interactive and illustrated PowerPoint HACCP training presentation is supplied to train your food safety team in the preliminary steps to a Hazard analysis, the principles of HACCP and how to utilise the HACCP calculator in implementing your HACCP system.
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Training Software The interactive and illustrated PowerPoint HACCP, CODEX GMP and Pre-requisites training presentations are supplied with training software.
We have provided HACCP, CODEX GMP and Pre-requisites Multiple choice exams evaluate your staff's progress with graphic certificates to print out.
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Step Three: Project 22000 This contains all the project tools you will need to achieve ISO 22000 certification. In this part of the package you will find: Steering Group are established and briefed The Steering Group take control of the Project Plan established by Senior Management
Food Safety Management System Steering Group FSMS Team Member FSMS Team Leader FSMS Assistant Leader FSMS Team Members Name Position Qualification
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Project Plan The Steering Group use the Excel Project Plan developed by Senior Management as a step by step guide to implementing the Food Safety Management System.
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Project Planning Tasks 1) 2) 3) 4) 5) 6) Senior management demonstrate a commitment to food safety Senior management issue a food safety policy Senior management establish food safety objectives Senior management define the scope and boundaries of the FSMS. Senior management plan the establishment of the FSMS. Senior management provide adequate support to establish the FSMS. Senior management ensure there is adequate infrastructure and work environment. Senior management appoint a food safety team leader Senior management appoint the food safety team. FSMS responsibilities and authorities are documented and communicated Food safety communication systems are put in place Responsibility Senior Management Team Senior Management Team Senior Management Team Senior Management Team Senior Management Team Senior Management Team Senior Management Team Senior Management Team Senior Management Team Senior Management Team Senior Management Team Comments Completed in Step 2 Completed in Step 2 Completed in Step 2 Completed in Step 2 Completed in Step 2 Completed in Step 2 Due Date for Completion 10/1/10 10/1/10 10/1/10 10/1/10 10/1/10 10/1/10 Date Completed 9/1/10 9/1/10 9/1/10 9/1/10 9/1/10 9/1/10
7)
Completed in Step 2 Completed in Step 2 Completed in Step 2 Completed in Step 2 Completed in Step 2
10/1/10 10/1/10 10/1/10 10/1/10 10/1/10
9/1/10 9/1/10 9/1/10 9/1/10 9/1/10
8) 9) 10)
11)
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Project Task 18 Management establish, implement and maintain infrastructure and maintenance prerequisite programs (PRPs) to control food safety hazards The Steering Group now need to decide whether to implement the Food Safety Management System Template Prerequisite Programmes first or to allocate responsibility to determine how far existing prerequisite programmes meet the requirements of CODEX and ISO 22002:2009.
RECOMMENDED INTERNATIONAL CODE OF PRACTICE GENERAL PRINCIPLES OF FOOD HYGIENE
CODEX CAC/RCP 1-1969, Rev.4- 2003 SECTION I - OBJECTIVES 1.1 THE CODEX GENERAL PRINCIPLES OF FOOD HYGIENE: identify the essential principles of food hygiene applicable throughout the food chain (including primary production through to the final consumer), to achieve the goal of ensuring that food is safe and suitable for human consumption; recommend a HACCP-based approach as a means to enhance food safety; indicate how to implement those principles; and provide a guidance for specific codes which may be needed for - sectors of the food chain; processes; or commodities; to amplify the hygiene requirements specific to those areas. SECTION II - SCOPE, USE AND DEFINITION 2.1.1 The food chain This document follows the food chain from primary production to the final consumer, setting out the necessary hygiene conditions for producing food which is safe and suitable for consumption. The document provides a base-line structure for other, more specific, codes applicable to particular sectors. Such specific codes and guidelines should be read in conjunction with this document and Hazard Analysis and Critical Control Point (HACCP) System and Guidelines for its Application (Annex). 2.1.2 Roles of Governments, industry, and consumers Industry should apply the hygienic practices set out in this document to:
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provide food which is safe and suitable for consumption; ensure that consumers have clear and easily-understood information, by way of labelling and other appropriate means, to enable them to protect their food from contamination and growth/survival of foodborne pathogens by storing, handling and preparing it correctly; and maintain confidence in internationally traded food. Consumers should recognize their role by following relevant instructions and applying appropriate food hygiene measures. 2.2 USE Each section in this document states both the objectives to be achieved and the rationale behind those objectives in terms of the safety and suitability of food. 2.3 DEFINITIONS SECTION III - PRIMARY PRODUCTION OBJECTIVES: Primary production should be managed in a way that ensures that food is safe and suitable for its intended use. Where necessary, this will include: avoiding the use of areas where the environment poses a threat to the safety of food controlling contaminants, pests and diseases of animals and plants in such a way as not to pose a threat to food safety adopting practices and measures to ensure food is produced under appropriately hygienic conditions Rationale: To reduce the likelihood of introducing a hazard which may adversely affect the safety of food, or its suitability for consumption, at later stages of the food chain Compliant 3.1 ENVIRONMENTAL HYGIENE Comments Yes No Potential sources of contamination from the environment should be considered. In particular, primary food production should not be carried on in areas where the presence of potentially harmful substances would lead to an unacceptable level of such substances in food. 3.2 HYGIENIC PRODUCTION OF FOOD SOURCES Compliant Comments
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Tasks 18 Management establish, implement and maintain infrastructure and maintenance prerequisite programs (PRPs) to control food safety hazards If Senior Management have decided that the objective is to achieve FSSC 22000 Certification then the Steering Group now need to allocate responsibility to determine how far existing prerequisite programmes meet the requirements of ISO 22002:2009. Using the checklist below and a copy of Technical Specification ISO 22002 the delegated person should read the requirements in the relevant section of ISO 22002 and complete the form.
ISO 22002 CONFORMANCE ANALYSIS 4. Construction and Layout of Buildings ISO 22002 Requirements 4.1 General requirements 4.2 Environment 4.3 Locations of establishments 5. Layout of Premises Workspace ISO 22002 Requirements 5.1 General requirements Compliant Yes No Comments Compliant Yes No Comments
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Project Task 18 Corrective Actions The non-compliances identified in the assessment of compliance with the prescribed prerequisite programmes should be logged by the Food Safety Team Leader and the appropriate corrective action allocated and taken:
Date Prerequisite Clause Details of Non Conformance Identified by: Corrective Action Required Target Date Responsibility completion Completed Date
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HACCP Implementation Guide We will now go through a step by step guide to implementing your HACCP using our HACCP Calculator. Tasks 19 - 21 ISO 22000 requires all raw materials, ingredients, product-contact materials and the characteristics of end products to be described in documents to the extent needed to conduct the hazard analysis. Specifications for all Raw Materials, including Ingredients and Product Contact Materials should be obtained from all suppliers and held in a purchased raw materials file. Specifications should include sufficient detail for the identification and assessment of food safety hazards. For each item the specification should include includes: - Biological, chemical and physical characteristics - Composition of formulated ingredients including additives and processing aids - Origin - Method of production - Delivery method - Storage conditions/requirements - Details of packaging - Preparation and/or handling before use or processing - Food Safety Acceptance criteria - Intended use Use the Excel Sheet Product Description in HM 26 HACCP Calculator and/or HM 19 Product Description to assist you in compiling an end product description. The food safety team should use the form to assist in documenting the end product characteristics, including legal food safety requirements, for the purpose of conducting the Hazard Analysis. The product description may include: Product name Composition What will the purchaser will do with it Details of the packaging How the product is processed or manufactured
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Taking these factors into account a rating is given for probability and severity and entered into the HACCP Calculator: Firstly the Food Safety Team assess the likelihood of the hazard occurring and enter: - 1 for Highly Unlikely - 2 for Possible - 3 for Likely
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Task 30 The food safety team establish the operational PRPs Design and Redesign of Operational PRP(s) Operational PRP(s) should be documented by the Food Safety Team and include details of the Significant Hazards to be controlled, the control measures applied, the monitoring procedures (parameters, frequency and records), corrections and corrective actions to be taken when outside acceptable limits. For each control measure and operational PRP(s) responsibility and authority should be defined:
Step Name
Hazards Identified
Delivery of Ingredient A
Campylobacter spp.
Specific Details about the Hazard Enter details here such as risk from birds
Preventative Measure
Limits
Monitoring Procedures
Corrective Action
Responsibility
OPRP Record
Example covered and screened delivery area
No Contamination Always load under cover
Supervision by Warehouse Manager
Retrain Staff. Inspect delivery for contamination. Reject if contaminated
Goods In Manager
Good Receipt Record
Our Operational Prerequisite Programmes Manual has template procedures and records that can be used
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HACCP Plan
Critical Limits
Monitoring Procedures - measurements to be taken (or observations) method of measurement - devices used (including applicable calibration procedures) - frequency of monitoring - responsibility and authority for monitoring and evaluation of the monitoring results
Corrective Action
Responsibility
HACCP Record
Minimum / Maximum acceptable levels to ensure condition is in control
Action to be taken when outside of critical limits to regain control and ensure unsafe product is controlled
Who is taking the action
Where is it recorded
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Design of the HACCP Plan The Food Safety Team need to formulate and document a HACCP plan defining the hazards to be controlled, CCPs where hazards are controlled, critical limits and monitoring procedures at each CCP and action to be taken when critical limits are exceeded. The HACCP plan needs to define those responsible for performing monitoring procedures and the records where the monitoring results are recorded.
Task 32 The food safety team identify critical control points (CCP)s for each food safety hazard Critical Control Points are established using the decision tree as the latest step in the flow path where controls can be effectively administered for a particular Significant Food Safety Hazards.
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Control Measure Validation
Product Category Step Number Hazard Control Measure Validation Methods Third Party Scientific Validation Historical Knowledge Simulated Production Conditions Collection of Data in normal production Admissible in industrial practices Statistical Programmes Mathematical Modelling Conclusion Internal Validation Required? If so by which method? CCP/OPRP Confirmed Authorised by(Name): Signature: Applicable Yes No Comments
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Step Five: Food Safety Quality Management System Our Food Safety Management System contains the most comprehensive ISO 22000 documentation package that you will find anywhere on the web. In this bundle of certification tools you will find: Food Safety Quality Manual containing a set comprehensive procedures and record templates. HACCP manual containing food safety procedures and our unique HACCP Calculator. Laboratory manual including sample procedures and records. Prerequisite Programmes manual. Operational Prerequisite Programmes Manual. At this stage you can choose to totally implement the procedures supplied or pick those that are applicable to your process. Food Safety Quality Manual The Food safety Quality Manual contains 28 comprehensive top level procedures templates that form the foundations of your Food Safety Management System so you don't have to spend 1,000's of hours writing compliant procedures: QM 001 - Food Safety Quality Management System QM 002 - FSQM Manual Summary QM 003 - Document Control QM 004 - Customer, Statutory and Regulatory Conformance QM 005 - Record Control QM 006 - Management Commitment QM 007 - Quality and Food Safety Policy QM 007 - Quality and Food Safety Objectives QM 008 - Responsibility, Authority and Communication QM 009 - Management Review QM 010 - Resources and Training QM 011 - Infrastructure and Work Environment QM 012 - Product Realization and Contract Review QM 013 - Design and Development QM 014 - Purchasing, Orders and Verification of Purchased Materials QM 015 - Prerequisite Programmes QM 016 - Identification and Traceability QM 017 - Customer Property QM 018 - Planning Product Realisation and Contract Review
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QM 019 - Calibration QM 020 - Hazard Analysis and Critical Control Points System QM 021 - Verification, Validation and Improvement QM 022 - Customer Satisfaction QM 023 - Internal Audit QM 024 - Monitoring and Measuring QMS, Analysis of Data QM 025 - Control of Non-Conforming Product QM 026 - Corrective Action and Preventive Action QM 027 - Crisis Management QM 028 - Product Recall
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FSQMS Record Templates The Food Safety Quality Manual includes 50 record templates that support your Food Safety Management System procedures: QMR 001 QMR 002 QMR 003 QMR 004 QMR 005 QMR 006 QMR 007 QMR 008 QMR 009 QMR 010 QMR 011 QMR 012 QMR 013 QMR 014 QMR 015 QMR 016 QMR 017 QMR 018 QMR 019 QMR 020 QMR 021 QMR 022 QMR 023 QMR 024 QMR 025 QMR 026 QMR 027 QMR 028 QMR 029 QMR 030 QMR 031 QMR 032 QMR 033 QMR 034 QMR 035 QMR 036 QMR 037 Management Review Minutes Training Record Product Release Record Design and Development Records Supplier Assessment Record Validation Record Identification and Traceability Record Register of Customer Property Calibration Record Internal Audit Record Records of Non-conforming Product Corrective Action Request Form Preventative Action Request Form Supplier Self Assessment and Approval Form Equipment Commissioning Record Return to Work Form Hygiene Policy Staff Training Record Complaint Investigation Form Prerequisite Audit Checklist Knife Control Record Knife Breakage Report Goods in Inspection Record Equipment Cleaning Procedure Glass and Brittle Plastic Breakage Record Metal Detection Record First Aid Dressing Issue Record Cleaning Schedule Cleaning Record Engineering Hygiene Clearance Record Glass and Brittle Plastic Register GMP Audit Checklist Vehicle Hygiene Inspection Record Outgoing Vehicle Inspection Record Pre Employment Medical Questionnaire Visitor Questionnaire Product Recall Record Shelf Life Confirmation Record
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QMR 038 QMR 039 QMR 040 QMR 041 QMR 042 QMR 043 QMR 044 QMR 045 QMR 046 QMR 047 QMR 048 QMR 049 QMR 050 Accelerated Keeping Quality Log Goods In QA Clearance Label Maintenance Work Hygiene Clearance Form Changing Room Cleaning Record Colour Coding Red Process Areas Daily Cleaning Record for Toilets and Changing Rooms Drain Cleaning Procedure Filler Areas General Cleaning Procedure Product QA Clearance Label CIP Programmes Log Sample Filler Cleaning Record Pipe Diameter Flow Rate Conversion Table QC Online Check Sheet
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HACCP Manual containing the HACCP Calculator Sections included in the HACCP manual are as follows: HM 1 HACCP System HM 2 HACCP Team HM 3 HACCP Prerequisites HM 4 HACCP Scope and Product Information HM 5 HACCP Intended Use HM 6 HACCP Flowcharts HM 7 HACCP Flowchart Verification HM 8 Hazard Identification HM 9 Hazard Assessment HM 10 Identification and Assessment of Control Measures HM 11 Identification of Critical Control Points (CCPs) HM 12 Establishing Critical Limits for each CCP HM 13 Establishing a Monitoring System for each CCP HM 14 Establishing a Corrective Action Plan HM 15 Establishing Verification Procedures HM 16 Establishing HACCP Documents and Records HM 17 Review of the HACCP Plan HM 18 Flow Diagram HM 19 Product Description HM 20 Hazards HM 21 HACCP Validation HM 22 HACCP Plan HM 23 HACCP Verification Audit Summary HM 24 HACCP Calculator Guide Part 1 HM 25 HACCP Calculator Guide Part 2 HM 26 Hazard Assessment & Critical Control Point Calculator HM 27 HACCP Definitions HM 28 HACCP Verification Record HM 29 HACCP Steering Group Review HM 30 Raw Material Summary HM 31 Finished Product Summary HM 32 Decision Tree
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Laboratory Quality Manual A comprehensive Laboratory Quality Manual compliant with the CLAS standard (Campden Laboratory Accreditation Scheme) provided in Microsoft Word format. The laboratory quality manual includes template records, procedures and product sampling plans.
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Prerequisite Programmes Manual
A comprehensive set of 67 prerequisite programmes templates that you can use to define your Infrastructure and Maintenance Standards and including those defined in Technical Specification ISO 22002:2009 Part 1 Prerequisite programmes on food safety for food manufacturing: PRP 1 Prerequisite Programmes PRP 2 HACCP Prerequisite Programmes PRP 3 Manufacturing Control Prerequisite Programmes PRP 4.1 Design and Construction of Buildings PRP 4.2 Environment Prerequisite Programmes PRP 4.3 Site Location and Standards PRP 5.1 Layout of Premises and Workspace PRP 5.2 Internal Design and Layout PRP 5.3 Internal Structure PRP 5.4 Equipment Design and Location PRP 5.5 Laboratory Facilities PRP 5.6 Temporary Structures and Vending Machine Facilities PRP 5.7 Storage PRP 6.1 Site Services PRP 6.2 Control of Water Supply PRP 6.3 Control of Boiler Chemicals PRP 6.4 Control of Air Supply PRP 6.5 Control of Compressed Air and Gases
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PRP 6.6 Lighting PRP 7.1 Waste Management PRP 7.2 Waste Container Management PRP 7.3 Waste Disposal PRP 7.4 Drainage Systems PRP 8.1 Equipment Prerequisite Programmes PRP 8.2 Equipment Hygienic Design PRP 8.3 Food Contact Surfaces PRP 8.4 Monitoring Equipment PRP 8.5 Equipment Cleaning PRP 8.6 Maintenance Prerequisite Programmes PRP 9.1 Purchasing Prerequisite Programmes PRP 9.2 Supplier Approval and Monitoring PRP 9.3 Control of Incoming Materials PRP 10.1 Prevention of Contamination PRP 10.2 Prevention of Microbiological Contamination PRP 10.3 Allergen Control System PRP 10.4 Prevention of Physical Contamination PRP 11.1 Cleaning Prerequisite Programmes PRP 11.2 Cleaning Agents and Equipment PRP 11.3 Cleaning Procedures PRP 11.4 CIP Systems Prerequisites PRP 11.5 Monitoring of Cleaning Effectiveness PRP 12.1 Pest Control Prerequisites PRP 12.2 Pest Control Programme PRP 12.3 Prevention of Pest Access PRP 12.4 Prevention of Pest Harbourage PRP 12.5 Pest Monitoring PRP 12.6 Pest Eradication PRP 13.1 Personal Hygiene and Personnel Facilities Prerequisites PRP 13.2 Personnel Hygiene Facilities PRP 13.3 Personnel Canteen Facilities PRP 13.4 Protective Work Wear PRP 13.5 Medical Screening PRP 13.6 Illness Reporting Systems PRP 13.7 Personal Cleanliness PRP 13.8 Personal Behaviour PRP 14.1 Rework Prerequisite Programmes PRP 14.2 Rework Storage Identification and Traceability PRP 14.3 Rework Usage Prerequisites PRP 15.1 Product Recall Prerequisite Programmes
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PRP 15.2 Product Recall Procedure Prerequisites PRP 16.1 Storage Prerequisites PRP 16.2 Warehousing Prerequisites PRP 16.3 Despatch and Distribution Prerequisites PRP 17.1 Product Information Prerequisites PRP 17.2 Product Labelling Controls PRP 18.1 Food Defence System PRP 18.2 Access Controls
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Prerequisite Programmes Verification Records 64 Verification audit templates covering all the prerequisite programmes: PRP 4.1 Design and Construction of Buildings Verification Audit PRP 4.3 Site Location and Standards Verification Audit PRP 5.1 Layout of Premises and Workspace Verification Audit PRP 5.2 Internal Design and Layout Verification Audit PRP 5.3 Internal Structure Verification Audit PRP 5.4 Equipment Design and Location Verification Audit PRP 5.5 Laboratory Facilities Verification Audit PRP 5.6 Temporary Structures and Vending Machines Verification Audit PRP 5.7 Storage Verification Audit PRP 6.1 Site Services Verification Audit PRP 6.2 Control of Water Supply Verification Audit PRP 6.3 Control of Boiler Chemicals Verification Audit PRP 6.4 Control of Air Supply Verification Audit PRP 6.5 Control of Compressed Air and Gases Verification Audit PRP 6.6 Lighting Verification Audit PRP 7.1 Waste Management Verification Audit PRP 7.2 Waste Container Management Verification Audit PRP 7.3 Waste Disposal Verification Audit PRP 7.4 Drainage Systems Verification Audit PRP 8.1 Equipment Prerequisite Programmes Verification Audit PRP 8.2 Equipment Hygienic Design Verification Audit PRP 8.3 Food Contact Surfaces Verification Audit PRP 8.4 Monitoring Equipment Verification Audit PRP 8.5 Equipment Cleaning Verification Audit PRP 8.6 Maintenance Prerequisite Programmes Verification Audit PRP 9.1 Purchasing Prerequisite Programmes Verification Audit PRP 9.2 Supplier Approval and Monitoring Verification Audit PRP 9.3 Control of Incoming Materials Verification Audit PRP 10.1 Prevention of Contamination Verification Audit PRP 10.2 Prevention of Microbiological Contamination Verification Audit PRP 10.3 Allergen Control System Verification Audit PRP 10.4 Prevention of Physical Contamination Verification Audit PRP 11.1 Cleaning Prerequisite Programmes Verification Audit PRP 11.2 Cleaning Agents and Equipment Verification Audit PRP 11.3 Cleaning Procedures Verification Audit PRP 11.4 CIP Systems Prerequisites Verification Audit PRP 11.5 Monitoring of Cleaning Effectiveness Verification Audit PRP 12.1 Pest Control Prerequisites Verification Audit
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PRP 12.2 Pest Control Programme Verification Audit PRP 12.3 Prevention of Pest Access Verification Audit PRP 12.4 Prevention of Pest Harbourage Verification Audit PRP 12.5 Pest Monitoring Verification Audit PRP 12.6 Pest Eradication Verification Audit PRP 13.1 Personal Hygiene and Personnel Facilities Verification Audit PRP 13.2 Personnel Hygiene Facilities Verification Audit PRP 13.3 Personnel Canteen Facilities Verification Audit PRP 13.4 Protective Work Wear Verification Audit PRP 13.5 Medical Screening Verification Audit PRP 13.6 Illness Reporting Systems Verification Audit PRP 13.7 Personal Cleanliness Verification Audit PRP 13.8 Personal Behaviour Verification Audit PRP 14.1 Rework Prerequisite Programmes Verification Audit PRP 14.2 Rework Storage Identification and Traceability Verification PRP 14.3 Rework Usage Prerequisites Verification Audit PRP 15.1 Product Recall Prerequisite Programmes Verification Audit PRP 15.1 Product Recall Procedure Prerequisites Verification Audit PRP 16.1 Storage Prerequisites Verification Audit PRP 16.2 Warehousing Prerequisites Verification Audit PRP 16.3 Despatch and Distribution Prerequisites Verification Audit PRP 17.1 Product Information Prerequisites Verification Audit PRP 17.2 Product Labelling Controls Verification Audit PRP 18.1 Food Defence System Verification Audit PRP 18.2 Access Controls Verification Audit
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Operational Prerequisite Programmes Manual
A set of 16 comprehensive operational prerequisite programmes including matching validation records and verification records: OPRP 1 Hygiene and Housekeeping Management OPRP 2 Management of Pest Control OPRP 3 Control of Visitors and Sub-Contractors OPRP 4 Management of Cleaning OPRP 5 Despatch and Distribution OPRP 6 Maintenance OPRP 7 Hygiene Policy OPRP 8 Hygiene Code of Practice OPRP 9 Glass Policy OPRP 10 Ingredients Foreign Body Control Policy OPRP 11 Metal Detection OPRP 12 Nut Handling Procedure OPRP 13 Control of Knives OPRP 14 Control of Brittle Materials OPRP 15 Glass & Brittle Material Breakage Procedure OPRP 16 Control of First Aid Dressings
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Operational Prerequisite Programmes Manual
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Operational Prerequisite Programme Validation Records OPRP 1 Hygiene and Housekeeping Management Validation OPRP 2 Management of Pest Control Validation OPRP 3 Control of Visitors and Sub-Contractors Validation OPRP 4 Management of Cleaning Validation OPRP 5 Despatch and Distribution Validation OPRP 6 Maintenance Validation OPRP 7 Hygiene Policy Validation OPRP 8 Hygiene Code of Practice Validation OPRP 9 Glass Policy Validation OPRP 10 Ingredients Foreign Body Control Policy Validation OPRP 11 Metal Detection Validation OPRP 12 Nut Handling Procedure Validation OPRP 13 Control of Knives Validation OPRP 14 Control of Brittle Materials Validation OPRP 15 Glass & Brittle Material Breakage Procedure Validation OPRP 16 Control of First Aid Dressings Validation
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Operational Prerequisite Programme Verification Records OPRP 1 Hygiene and Housekeeping Management Verification OPRP 2 Management of Pest Control Verification OPRP 3 Control of Visitors and Sub-Contractors Verification OPRP 4 Management of Cleaning Verification OPRP 5 Despatch and Distribution Verification OPRP 6 Maintenance Verification OPRP 7 Hygiene Policy Verification OPRP 8 Hygiene Code of Practice Verification OPRP 9 Glass Policy Verification OPRP 10 Ingredients Foreign Body Control Policy Verification OPRP 11 Metal Detection Verification OPRP 12 Nut Handling Procedure Verification OPRP 13 Control of Knives Verification OPRP 14 Control of Brittle Materials Verification OPRP 15 Glass & Brittle Material Breakage Procedure Verification OPRP 16 Control of First Aid Dressings Verification
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Below is a table that matches the requirements of the ISO 22000 standard with the Food Safety Management System provided to assist you in implementing the system and understanding the requirements of the standard. ISO 22000 Clause FSMS Manual Reference
ISO 9001 Clause
Policy / Procedure Title
4. Quality Management System (ISO 9001) 4. Food Safety Quality Management System (ISO 22000) 4.1 General Requirements 4.2 Documentation 4.2.2 Document Control 4.2.2 Document Control 4.2.3 Record Control 4.1 General Requirements 4.2 Documentation 4.2.3 Internal Document Control 4.2.4 External Document Control 4.5 Quality System Records QM001 QM002 QM003 Quality and Food Safety Management System QMS Manual Summary Document Control
QM004 QM005
Customer, Statutory and Regulatory Conformance Record Control
5. Management Responsibility 5.1 Management Commitment 5.1 Management Commitment QM006 Management Commitment
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Step Five: Internal Auditing Training & Checklists This is a package of ISO 9001 and ISO 22000 PowerPoint internal auditor training guides plus a set of ISO 9001, ISO 22000 and BRC global standard for food safety internal auditing checklists that can also be used as gap analysis checklists. There are PowerPoint training presentations and audit checklists which cover the complete auditing process will cover management responsibility, planning and realization of safe products, resources management, validation, verification and improvement, and much more...
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Internal Auditing Training & Checklists
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Internal Auditing Training & Checklists
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Task 47 The senior management team carry out food safety management reviews Senior management should review the company management systems, at a minimum, annually to ensure their continuing suitability, adequacy and effectiveness. The review should includes assessing opportunity for improvements and the need for amendments to the systems. The proceedings of all reviews are to be documented. The review meeting is normally chaired by the most Senior Manager and includes Senior Management from Technical, Operations, Engineering, Planning, Distribution and quality departments. Review should inputs include: Review of the Quality and Food Safety Policy Review of Management Changes Minutes and Follow-up actions from previous review meetings Outstanding Non-conformances as a result of internal and external audits Results of external second and third-party audits Trend analysis of Customer and Supplier complaints Analysis of the results of verification activities including internal hygiene and HACCP plan verification audits Quality Key Performance Indicators Review and trend analysis Emergencies and Accidents Process performance and product conformity Corrective and preventive action status Food Safety incidents including allergen control and labelling, recalls, withdrawals, safety or legal issues Review of planning and development of the processes needed for the realisation of safe products including changes which could affect food safety and the HACCP Plan (including legislation changes and scientific information) Changes to policies and objectives Communication activities and effectiveness of communication Results of review and system updating Review of Resources and effectiveness of Training Recommended improvements Customer Feedback and Sales levels are reviewed to give an indication of trends
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Attendees:
Senior Management Team Job Title Managing Director Site Director Operations Manager Technical Manager Planning Manager Distribution Manager Maintenance Manager Finance Manager Human Resources Manager Name Role in Team Chairman Deputy Chair Operations Reporting Food Safety and Quality Reporting Management Representative Planning and Capacity Reporting Distribution Reporting Services and Engineering Provision Financial Reporting Resource reporting
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Task 49 The food safety team update the FSMS as necessary by reviewing data collected and information The Food Safety Team should be informed in a timely manner of changes including the following: products or new products raw materials, ingredients and services production systems and equipment production premises, location of equipment, surrounding environment cleaning and sanitation programmes; packaging, storage and distribution systems personnel qualification levels and/or allocation of responsibilities and authorizations statutory and regulatory requirements knowledge regarding food safety hazards and control measures customer, sector and other requirements that the organization observes relevant enquiries from external interested parties complaints indicating food safety hazards associated with the product other conditions that have an impact on food safety.
The Food Safety Team should carry out evaluation and updating of the Food Safety Management System at regular intervals based on: input of changes as above input from other information concerning the suitability, adequacy and effectiveness of the food safety management system output from the analysis of results of verification activities output from management review The Food Safety Team evaluation and updating of the Food Safety Management System should be documented, reported and used as an input to the Senior Management review.
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Stage 8 Final Steps to ISO 22000 Certification There a few final steps to achieving ISO 22000 Certification: Carry out an assessment of your system to make sure that it meets the requirements of the ISO 22000 standard using our ISO 22000 Checklists Ensure any areas requiring corrective action are addressed Choose your Certification Body Make contact with the Certification Body Pre-assessment Formal assessment Certification Celebrate! Communicate your success! Carry out an assessment of your system to make sure that it meets the requirements of the ISO 22000 standard using our ISO 22000 Checklists: Using our comprehensive ISO 22000 Requirements Checklists assess your food safety management system to ensure that you are satisfied that it meets the requirements of the standard:
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ISO 222000 Food Safety Management System Requirements Internal Audit ISO 22000 Section 4.1 General Requirements Has an effective food safety management system been documented and implemented? Is the FSMS maintained and updated? Has the scope of the food safety management system been defined including the products or product categories, processes and production sites? Does the FSQMS ensure that food safety hazards are identified, evaluated and controlled? Is there communication of appropriate information throughout the food chain regarding safety issues? Is there communication of information regarding development, implementation and updating of the food safety management system throughout the organization? Does the FSQMS incorporate the most recent information on the food safety hazards subject to control? Is control of outsourced processes identified and documented within the food safety management system. 4.2 Documentation Requirements Is there a documented food safety policy and objectives? Is there sufficient documentation to ensure the effective development, implementation and updating of the food safety management system. 4.2.2 Control of Documents Are food safety management system documents controlled? Audit Findings
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Ensure any areas requiring corrective action are addressed The non-compliances identified in the assessment of compliance with ISO 22000 should be logged by the Food Safety Team Leader and the appropriate corrective action allocated and taken:
Date ISO 22000 Clause Details of Non Conformance Identified by: Corrective Action Required Target Date Responsibility completion Completed Date
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Choose your Certification Body Before you can begin preparing for your application, youll need to decide which Certification Body to use. Do some research and pick one which has a good reputation, after all you will have their logo on your certificate! Make contact with the Certification Body Contact the Certification Body and tell them what you need. They should provide you with a proposal detailing the cost and time involved in a formal assessment. Pre-assessment Arrange a pre-assessment of your food safety management system with the Certification Body. Formal Assessment Arrange your formal assessment which will be conducted on site. Certification Once the assessment has been successfully completed the Certification Body will issue a certificate of registration for your food safety management system. The certificate is normally valid for three years subject to satisfactory surveillance visits during this period.
For more information e-mail me at tony@22000foodsafety.com Click here to order our Assured Food Safety Management System Certification Package
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Sample of The Assured FSMS Certification Workbook

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ISO 22000 Food Safety Management System Implementation Workbook

For more information e-mail me at tony@22000foodsafety.com

ISO 22000 Food Safety Management System Implementation Workbook

ISO 22000 Food Safety Management System Implementation Workbook

ISO 22000 Food Safety Management System Implementation Workbook

ISO 22000 Food Safety Management System Implementation Workbook

Responsible Persons Purchasing Manager

Receiving and warehousing

QA/QC & Store Executives

Holding and Filling of Processed Food

Production Supervisor & Operators Production Supervisor & Operators

Capping, coding and packing

ISO 22000 Food Safety Management System Implementation Workbook

ISO 22000 Food Safety Management System Implementation Workbook

ISO 22000 Food Safety Management System Implementation Workbook

ISO 22000 Food Safety Management System Implementation Workbook

ISO 22000 Food Safety Management System Implementation Workbook

ISO 22000 Food Safety Management System Implementation Workbook

ISO 22000 Food Safety Management System Implementation Workbook

ISO 22000 Food Safety Management System Implementation Workbook

ISO 22000 Food Safety Management System Implementation Workbook

ISO 22000 Food Safety Management System Implementation Workbook

ISO 22000 Food Safety Management System Implementation Workbook

ISO 22000 Food Safety Management System Implementation Workbook

ISO 22000 Food Safety Management System Implementation Workbook

ISO 22000 Food Safety Management System Implementation Workbook

10/1/10 10/1/10 10/1/10 10/1/10 10/1/10

9/1/10 9/1/10 9/1/10 9/1/10 9/1/10

ISO 22000 Food Safety Management System Implementation Workbook

ISO 22000 Food Safety Management System Implementation Workbook

ISO 22000 Food Safety Management System Implementation Workbook

ISO 22000 Food Safety Management System Implementation Workbook

ISO 22000 Food Safety Management System Implementation Workbook

ISO 22000 Food Safety Management System Implementation Workbook

ISO 22000 Food Safety Management System Implementation Workbook

Example covered and screened delivery area

No Contamination Always load under cover

Supervision by Warehouse Manager

Retrain Staff. Inspect delivery for contamination. Reject if contaminated

Good Receipt Record

ISO 22000 Food Safety Management System Implementation Workbook

Minimum / Maximum acceptable levels to ensure condition is in control

Who is taking the action

ISO 22000 Food Safety Management System Implementation Workbook

ISO 22000 Food Safety Management System Implementation Workbook

ISO 22000 Food Safety Management System Implementation Workbook

ISO 22000 Food Safety Management System Implementation Workbook

ISO 22000 Food Safety Management System Implementation Workbook

ISO 22000 Food Safety Management System Implementation Workbook

ISO 22000 Food Safety Management System Implementation Workbook

ISO 22000 Food Safety Management System Implementation Workbook

ISO 22000 Food Safety Management System Implementation Workbook

ISO 22000 Food Safety Management System Implementation Workbook

ISO 22000 Food Safety Management System Implementation Workbook

ISO 22000 Food Safety Management System Implementation Workbook

ISO 22000 Food Safety Management System Implementation Workbook

ISO 22000 Food Safety Management System Implementation Workbook

ISO 22000 Food Safety Management System Implementation Workbook

ISO 22000 Food Safety Management System Implementation Workbook

ISO 22000 Food Safety Management System Implementation Workbook

ISO 22000 Food Safety Management System Implementation Workbook

ISO 22000 Food Safety Management System Implementation Workbook