copyright richard f. stier 2011 building preventive maintenance programs to save money and enhance...

COPYRIGHT RICHARD F. STIER 2011

Building Preventive Maintenance Programs to Save Money and

Enhance Efficiencies

Richard F. StierConsulting Food Scientist

Sonoma, CA [email protected]

mailto:[email protected]


PREVENTIVE MAINTENANCE

COMMON EXAMPLES• Teeth Cleaning - 2x per year to prevent decay

• Oil Changes - Protect car’s engine

• Tree Trimming - Protect house from damage

• Gutter Cleaning - Protect roof & home


WHY YOU MAINTAIN YOUR CAR



WHY• Assure food safety• Reduce potential for adulteration• Protect equipment/extend life

– Significant savings

• Enhance profitability• Records of performance• Integral part of all 3rd party audits


How To Make Safe Food

HACCP

GMP/GAP

SANITATION PRODUCT IDENTIFICATION & CODING,

RECALL & TRACEABILITY,

PREVENTIVE MAINTENANCE, EDUCATION & TRAINING, AND OTHER PREREQ PROGRAMS

SAFE FOOD

Total Management Commitment


Prerequisites and FSSC 220008.6 Preventive and Corrective Maintenance

A preventive maintenance program shall be in place

The preventive maintenance programme shall include all devices used to monitor and control food safety hazards


CAC/RCP 1-1969, Rev.4- 2003 Page 1 of 31

RECOMMENDED INTERNATIONAL CODE OF PRACTICE

GENERAL PRINCIPLES OF FOOD HYGIENE

CAC/RCP 1-1969, Rev. 4-20031

TABLE OF CONTENTS


SECTION VI – ESTABLISHMENT MAINTENANCE & SANITATION

• Maintenance & Cleaning – General Establishment & equipment should be kept in

an appropriate state of repair to:– Facilitate sanitation procedures – Function as intended– Prevent contamination of food

Cleaning should remove food residues. Method depends on type of soil. Disinfection may be necessary after cleaning. Use cleaning materials per manufacturers instructions.


HACCP PLAN DEVELOPMENT

FLOW CHART OPERATIONS

• Understand the process

• Means of conveyance & transfers

• Understand what needs to be maintained



BIOLOGICAL HAZARDS

• Loss of process control

• Contamination with foodborne pathogens

• Growth of foodborne pathogens

• Inability to properly monitor systems



TEMPERATURE CONTROL

• Malfunctioning temperature indicating or temperature recording devices

• Belt Failures - Residence for continuous processes shortened

• Pumps - Residence time reduced

• Refrigeration Failures



PACKAGING FAILURES

• Botulism in canned salmon (early 1980’s)

• Seamer adjustment failures (post-process contamination)

• Sealer failures


FOOD PLANT CHEMICALS

• Food additives– Vitamins– Sulfites

• Lubricants

• Sanitizers

• Cleaners

• Antimicrobials



CHEMICAL HAZARDS

• Improper lubrication (excessive)

• Cleaners

• Failure to use food-grade/approved materials



PHYSICAL HAZARDS

• Missing bolts

• Worn belts

• Metal to metal contact

• Broken blades, choppers, etc.

• Glass windows

• Protected bulbs



PHYSICAL HAZARDS

• Metal detectors improperly maintained or calibrated

• Can or glass washers

• Buildings not maintained (rust, flaking paint)


ESTABLISHING PREVENTIVE MAINTENANCE PROGRAMS

THREE STEP PROGRAM

• Inventory & Understand Equipment - Flow Chart

• Develop Standard Operating procedures for Inspection & Maintenance

• Develop Recordkeeping Procedures to Document Maintenance


INVENTORY & UNDERSTAND EQUIPMENT• Process Flow Charts

• Potential for Hazards

• Units Essential to Food Safety

• Equipment Setup Properly; Example, Motors over processing lines

• Accessibility


DEVELOP SOP’S for INSPECTION & MAINTENANCE

• Work with Suppliers: – Operating Manuals

– Training

• Inspections - Routine & Detailed

• Write Protocols - Date & Sign Off

• Place in a Manual


DEVELOP RECORDKEEPING PROTOCOLS

• Develop monitoring forms - keep simple– Include forms for emergency repairs– Lubrication records– Tool reconciliation

• Essential element for HACCP & ISO and many buyers

• Maintenance records can be used to evaluate performance

• Record review policy by management


DATEBASES: WHY??• Organization

• Stronger prerequisite programs

• Reduced liability

• Enhanced efficiencies

• Safer work environment

• Improved quality

• Audit requirements


MAINTENANCE MANAGEMENT• Many commercial products

– SAP, Blue Mountain, AMMS, others

• Many companies still use “hard copies” to manage this prerequisite program

• Painful to get set up• Lots and lots of data that must be entered• Most companies whom I have worked with are not

even using their programs at full capacity


MAINTENANCE MANAGEMENT

• What you want– Maintenance scheduling– Flags when items are due– Flags for past due items– Cost integration – Maintenance hours, capital costs, parts,

downtime, etc.– Procedures for doing work– Automatic entry by workers– Ability to verify that work has been done– Print capability – Summaries, schedules, equipment

registers– Ability to “talk” to other systems


INCLUDE CALIBRATION• Essential element for ensuring food safety and

quality• All devices used for monitoring CCPs must be

calibrated on a regular schedule• All devices used for quality monitoring must

be calibrated• Commercial systems – Some incorporate

calibration into their maintenance management systems

• Developed in-house – EXCEL, ACCESS


IN-PLANT COOPERATION

• All operating groups must participate in equipment upkeep & maintenance– Many companies pass on routine maintenance

and startup to production personnel

• Report problems immediately• Report on performance• Encourage input on maintenance & upkeep• Adherence to cleaning & sanitizing


SANITATION & MAINTENANCE

• Maintenance staff must adhere to basic principles of sanitation

• Hair restraints, cleanliness, proper clothing

• Tools & supplies under control

• Conscious of processing


IMPLEMENTATION

• Do not try to do all at once

• Work with one line or area

• Be flexible

• Modify program as needed


RESPONSIBLEPERSON


Responsible Person• Someone must be assigned to manage the preventive

maintenance program– Engineering Manager

– Shop supervisor

• Person should;– Write or update procedures

– Manage scheduling of training

– Review and maintain training records

– Ensure that program is audited per schedules, i.e., the program is be followed as designed.


Responsible Person

• Job description should reflect responsibility• Person must sign job description or another

document acknowledging responsibility• Must manage training program to ensure that all

necessary training is delivered.• Training must be based on documented

procedures


TRAINING/EDUCATION

• Production and maintenance personnel must be trained– Work instructions– Procedures

• Quality, safety and sanitation


DOCUMENTEDPROCEDURES


Procedures

• Procedures must be developed, documented, implemented & maintained– Standard format for each procedure– Should include a general protocol that

addresses each area of the preventive maintenance program

– Can be integrated into maintenance management software


Procedures• Procedures must be developed, documented,

implemented & maintained– Created by;

• Maintenance staff• Vendors• Other

– Recordkeeping forms– Must include;

• Regular maintenance• Emergency maintenance• Lubrication

– Record review procedures– Audit scheduling & format– Register format for equipment


RECORDS


RECORDKEEPING

“If it’s not written down it never happened.”

United States Food & Drug Administration


RECORDKEEPING “In God we trust. But everyone else

has to give us data and records.”


RECORDS • Maintenance records must be maintained• May be;

– Hard copies– Electronic databases

• Records must include;– Tasks– Records of completion– Verification that work was done– Training/competency records

• Certified electrician, plumber, etc


SYSTEMAUDITS


System Verification

• Procedures – Persons responsible for doing work following

established procedures– Use procedures and work instructions as a

guide

• Records– Adherence to schedules– Training records– Audit forms


System Verification• Internal auditors must be trained to do audits

– Procedures

– Forms

– What to look for

– Training records maintained

• Can be done in-house or send to a 3rd party for training

• Realistically, in-house may be better since training may be “hands-on”


System Audits• Persons doing work complying with documented

procedures and/or work instructions• Persons trained or competent

– Training records on procedures

– Records demonstrating competency

• Records being kept properly– Data recorded when record or observation taken

– Corrections made properly

– Proper pens and forms employed

– Other


System Audits

• Corrective Actions– Deficiencies must be addressed – Corrective or preventive actions– Serious deficiencies should be subjected to root cause

analysis to determine why the issue occurred– Maintain records of actions

• Forms• CAPA log

– Persons must be trained in root cause analysis procedures

– Quality group shall verify that deficiencies were addressed. Sign & date corrective action programs



• Three Part Implementation– Inventory & Understand Equipment

– Develop Procedures for Inspection & Maintenance

– Develop Recordkeeping Procedures

• Involve All Operating Groups

• Implement Program Gradually



• Help to Assure Food Safety• Help to Assure Food

Quality• Minimize Product

Adulteration• Enhance Efficiencies• Save MONEY

copyright richard f. stier 2011 building preventive maintenance programs to save money and enhance...

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