Food Industry - Quality Assurance - HACCP - ISO 22000

Course description

• The Doctrine of Liability

• The "Total Accountability"

• Management and Product Quality

• Organizational Plan

• Total Quality Program

• The Working Environment

• Workers

• Managers and Supervisors

• Building Teams of Empowered Employees

• Employee Training

• Work Teams and Empowerment

• Quality at the Source
• Steering Committees or QC Circles

• What Is Quality?

• Dimensions of Quality

• Standards of Quality

• Methods for Determining Quality

• Subjective Methods

• Objective Methods

• Differentiation between Cell Types Tissue Types, and

• Microorganisms of Various Stored Foods

• Official Methods of Analysis in the Food Industry

• The Association of Analytical Communities International

• The American Association of Cereal Chemists

• The American Oil Chemists' Society

• The American Public Health Association

• The American Spice Trade Association

• Total Quality Management

• Theories and Application

• The Concept of Total Quality Management

• The Basis for Superior Quality Performance

• TQM and ISO

• The Structure of TOM

• The Principles of TQM

• The Steps to TQM

• Total Quality Management Tools

• Statistical Analysis Tools

• Datasheet

• Cause-and-Effect Diagram

• Scatter Diagram

• Flowchart

• Histogram

• Control Than,

• X-Bar and R Charts

• p-Charts

• np-Charts

• Other Types of Charts

• Management and Planning Tools

• Affinity Diagrams

• Interrelationship Digraphs

• Tree Diagram

• Matrix Diagram

• Matrices

• Process Decision Program Chart

• Activity Network Diagram

• Gantt Chart

• Entity-Relationship Diagram

• TQM Vision and Mission

  Integrated Business Plan

  Some History of Total Quality Management

  The Pioneers of Scientific Quality Management

  Frederick Taylor

  Walter A Shewhart

  W Edwards Deming

  Joseph MJuran

• Armand V Feigenbaum

  Philip B Crosby

  The Japanese Contribution

  Kaoru Ishikawa

  Genichi Taguchi

  Quality Circles

  Present Utilization of TQM Programs

  Quality and Business Performance

  Service Quality vs Product Quality

  The Malcolm Baldrige National Quality Award

  The Malcolm Baldrige Award Criteria

• ---Quality Assurance

  Theories and Applications

  Functions of a Quality Assurance Program

  Quality Control

  Quality Evaluation

  Quality Audit

  Education and Training

  Process Improvement

  Standards

  Special Projects

  Consulting

  Auditing the Quality Program

  Careers in Quality Assurance

  QA Responsibilities and Operational Interactions

  The Need for and Roles of QA

  Organization of a QA Program

  QA Personnel

  The Vice President of QA

  QA Professionals

  QA Audits

• Procedures

  In Process Monitoring

  Statistical Procedures

  The Audit Report

  Types of Audits

  Product Manufacturing Audits

  Control of Nonconforming Products

  Corrective Action

  Plant Sanitation/GMP Audits

  Plant Facilities

  Employee Hygiene

• In-process Control

  Contamination and Adulteration

  Pest Control

  Product Quality Audits

  HACCP Audits

  Special Audits

  Document Control Audit Q

  Supplier Audits

  QC/instrument Calibration and Maintenance Audits

  Product Batch Preparation/Formulation Audits

  Quality Program Review

  QA Documentation System

  Quality Manual-

  SOP (Manufacturing and Quality) Documents

  PSM Documents

  GMO Documents"

  QCA Methods Documents

  CMP Documents -

  Equipment-Specific Sanitation Documents

  Pre-Operation Sanitation Documents

  Work Instructions

  Records

  HACCP Program Documents

• ----Ingredient Specifications and Supplier Certification

  Program

  Raw Material Ingredient Certification Programs

  Degree of Variability

  Flavour

  The Supplier Quality Program (SOP)

  Supplier Qualification

  Approved Vendors List

  Supplier HACCP Qualification Standards

  Supplier HACCP/QA Qualification List by Ingredients Purchased

  Ingredient Specification/Certification

  Supplier Auditing

  Certificate of Analysis

  Third-Party Inspections

  Buying from Agents and Brokers

  Identity-Preserved Products: A New Fowl Production Scenario

  Defining IP Products

  Consumer Desire*

  Processing Improvements

  Product Attributes

• ---Statistical Methods of Quality Control in the Food

  Industry-

  Introduction

  Statistical Tools and Strategics for Process Control Improvement

  Design and Analysis of Analytic Studies

  Definitions of Terms and Concepts

  Single Factor Experiments

  The ANOVA Methods

  The Randomized Complete Block Design: Two-Way ANOVA

  Quality Control Techniques

  Variable Control Charts

  X and R Control Chart

  X and S Control Chart

• Attribute Control Charts

  P-Charts

  np-Charts

• ---Manufacturing Audits: Control of Processing

  Operations

  Objectives of Process Control

  Elements of Process control

  Education and Training

  Process Control Documentation

  Unit Operations in the Food Industry

  Materials Handling

  Cleaning

  Separation

  Disintegration

  Pumping

  Mixing

  Heating

  Cooling

  Evaporating;

  Drying

  Packaging

  Controlling

  Overlapping Unit Operations

  Product Manufacturing Audits

  Planning the Audit

  Documentation

  Product-Specific Manufacturing (PSM) Procedures

  General Manufacturing Procedures

  Standard Sanitary Operation Procedures

  Analytical Control Procedures

  Definitions,

  Quality Management Areas (Unit Operations)

  Product-Dependent Operations

  Product-Independent Operations

  Process Control Points

  Batching

  Manufacturing Procedure Deviations

  Risk Deviations

  Non risk Deviations

  Non-risk Deviations to Risk Requirements

  Audit Deviations: Example

  Deviations from the Manufacturing Program

  Batching and Formulation Practices

  Traditional Chocolate Manufacturing Line

  De Lux Chocolate Manufacturing Line

  Strawberry Topping Manufacturing Line

  Ingredient Qualification and Storage Program

  Ingredient Analysis Program

  Analytical Test Methods

  Consistency lira bender

  IACCP Analysis

  Batching and Formulation Program

  Granular Sugar - Weighing Scale

  Strawberry Topping Batching

  Maple Walnut Topping

• ---Food Plant Sanitation: Good Manufacturing Practice

  Audits

  Food Plant Sanitary Practices

  Food Contamination

  Humans

  Air and Waters

  Sewage

  Insects Rodents and Birds

  The Value of a Planned Sanitation Program

  Storage Facilities

  Litter and Garbage Disposal

  The Sanitation Audit Report

  Report Format

  Example of a Plant Sanitation Audit Report

• --- Product Quality Audits at the Retail Level

  Definition

  Objectives

  Procedure

  Planning

  Preliminary Review Meeting

  Protocol

  Departments Involved

  Product Sampling

  Product Pick-Up

  Testing

  Packaging Quality

  Sensory Evaluation

  Analytical Testing

  Example of a Product Quality Audit

  Objectives

  Protocol

  Comparison between Eureka and Classic Beef Stew Products

  Age

  Drained Weight

  Bostwick Value

  pH

  °Brix

  Salt

  Colour Agtron

  Sensor Evaluation

  Eureka Beef Stew

  Classic Beef Stews

• --- Hazard Analysis and Critical Control Points

  Introduction

  The HACCP Concept

  The Importance of HACCP

  Advantages

  The HACCP Program

  Guidelines for Application of the HACCP Principles

  HACCP Program Prerequisites

  Education and Training

• Development of ail HACCP Program

  The Preliminary Tasks of an HACCP Program

  Choosing the HACCP Team

  Description of the Food Product and Its Distribution

  Description of the Intended Use and Consumers of the Product

  Development of a Flow Diagram Describing a Food Product

  Manufacturing Process

  Verification of the Flow Diagram

  The Seven HACCP Principles

  Principle I: Conduct a Hazard Analysis

  Categories of Hazards

  Biological Hazards

  Chemical Hazards

  Physical Hazards

  Preventive Measures

  Questions to Consider when Conducting a Hazard Analysis

  Ingredients

  Intrinsic Factors

  Procedures Used for Processing

  Microbial Content of the Food

  Facility Design

  Equipment Design and Use

  Packaging

  Sanitation

  Employee Health, Hygiene, and Education

• Conditions of Storage between Packaging and the End User

• Intended Consumer

  Hazard identification

  The Raw Materials

  The Manufacturing Process

  Control Measures

  Risk Categories

  Documentation

  Special Considerations when Conducting a Hazard Analysis

  Deciding which Potential Hazards Must be addressed

  In the HACCP Program

  Principle: CCP Identification

  Preventive Critical Control Measures (Microbiological)

  CCP Decision Tree

  Principle: Establish Critical limits for Each CCP

  Principle: Establish CCP Monitoring Procedures

  Visual Observations

  Sensory Evaluations

  Physicochemical Evaluations

  Microbiological Analysis

• Principle: Establish Corrective Actions Procedures

  Identifying Causes of Deviations

  Determining Product Disposition

  Recording the Corrective Action

  Reevaluating The HACCP Plan

  Principle: Establish Procedures for HACCP Verification and Validation

  Verification

  Events that May Require Verification Inspection of the HACCP Plan

  HACCP Verification Protocol and Activities - Information

  In Verification Reports

  Verification Schedules

  Validation

  Principle: Document the HACCP Program Establishment of Record-Keeping Procedures

  Format for HACCP Information

  Examples of Records Required during Operation of the HACCP Program

  Implementation and Maintenance of an HACCP Program

  Practical Example: HACCP Plan Model for Refrigerated Stick and Sliced Celery

  The Scope of HACCP

  Regulatory Aspects of HACCP

  Sanitation and the HACCP Concept