teagacs brc issue_6_event_how_to_get_started
DESCRIPTION
BRC for Food Safety Issue 6 HOW TO GET STARTEDTRANSCRIPT
HOW TO GET STARTED
BRC Issue 6 Seminar Overview of Changes
HOW TO GET STARTED
Ulr ich Schraewer
QS-Development - BRC for Food Safety Version 6
About Us2
� Degree in Food Science & Technology
� Over 11 years experience working/auditing in the Food Industry
QS-Development - BRC for Food Safety Version 6
� ISO 9001 Lead Auditor
� BRC Certification Auditor
� IFS Food Certification Auditor
Overview3
� What to do first?
� Methods & tools explained on key-clauses of section 1 to 7
- Risk Assessment
QS-Development - BRC for Food Safety Version 6
- Risk Assessment
- Root Cause Analysis
- Plans
� Vertical Audit
What to do first?4
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Example: Cold Smoked Salmon5
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6
QS-Development - BRC for Food Safety Version 6
Low Risk/High Care/High Risk Clauses7
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� Filter specification
� Frequency of air changes
� Source of air
� Positive air pressure
Section 1: Senior Management Commitment
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At least monthly communication with management
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Other clauses with defined frequencies:
1.1.2 Quarterly monitoring of objectives3.4.4 Monthly inspections in open product areas3.9.2 Annually Traceability testing (achievable in 4 hours)4.13.8 Quarterly in-depth pest control surveys4.14.2 Four-hourly temp. check - if no alarm on temp. record equipment.
Section 2 : The Food Safety Plan - HACCP9
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2.7 Hazard Analysis10
Clause 2.7 in conjunction with clause 5.2.3
Third bullet point of clause 5.2.3:
� “Assessment of the risk of allergen cross-contamination
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� “Assessment of the risk of allergen cross-contamination
at each process step”
Section 3: FSQM-System11
3.4 Internal Audit (Fundamental)
“The scope and frequency of the audits shall be established in relation to the risks associated with the activity and
previous audit performance…” - Clause 3.4.1
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previous audit performance…” - Clause 3.4.1
RISK ASSESSMENT
Other clauses were risk assessment is required:
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� 3.4.4 Risk Assessment (RA) for the frequency of inspection
� 3.5.1.1 RA for each raw material or group of materials
� 4.5.1 RA for water sampling points and frequency
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� 4.10.6 RA to minimise foreign body contamination of packaging containers
� 4.11.1 RA for frequency and methods of cleaning
� 4.13.8 RA for the frequency of in-depth pest control surveys
� 6.3.2 RA frequency of checking measuring devices.
Example: Risk Assessment13
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Example: Risk Assessment14
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Section 3: FSQM-System15
3.7 Corrective Action (Fundamental)
1. “Verification that corrective action has been implemented and is effective.” – Clause 3.7.1
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implemented and is effective.” – Clause 3.7.1
2. “Identification of the root cause of the non-conformity….” – Clause 3.7.1
Example: Corrective Action16
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Root Cause Analysis17
Ł Ishikawa Diagram - http://en.wikipedia.org/wiki/Fishbone_diagram
Ł 5 Why’s - http://en.wikipedia.org/wiki/5_Whys
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Example: Root Cause with 5 Why’s18
1. Why was no review of the competencies of staff carried out? (Clause 7.1.5)
- QA Manager forgot.
2. Why did the QA Manager forget to carry out the review?
- The QA Manager did not check the review summary sheet.
3. Why didn’t the QA-Manager check the review summary sheet?
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3. Why didn’t the QA-Manager check the review summary sheet?
- The QA Manager did not get any reminder.
4. Why didn’t the QA Manager get any reminder?
- The QA Assistant was on holidays and there is no software to remind the QA-Manager.
5. Why is there no software with reminder option for reviews?
- A paper system instead of paperless system is used.
- Existing software is poor and does not provide review options.
Section 4: Site Standards19
4.3.1 Layout, product flow & segregation
4.4.4 Building fabric
4.5.2 Utilities
?QS-Development - BRC for Food Safety Version 6
4.5.2 Utilities
4.11.6.2 CIP
4.13.3 Pest Control
Plan or Schematic Plan is required
?
Section 4: Site Standards20
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METAL DETECTOR IS A MUST
OR
ABSOLUTELY WATERTIGHT RISK ASSESSMENT
Section 5: Product Control21
5.2 Management of Allergens
Risk Assessment required including:
“Consideration of the state of the allergenic material
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“Consideration of the state of the allergenic material
,i.e. powder, liquid, particulate.” – Clause 5.2.3
Ł http://www.food.gov.uk/multimedia/pdfs/maycontainguide.pdf
Ł http://allergytraining.food.gov.uk/english/default.aspx
Section 6: Process Control22
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Temperature Mapping
www.FSAI.ie – Guidance Note No. 2023
QS-Development - BRC for Food Safety Version 6
www.FSAI.ie – Guidance Note No. 2024
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Section 7: Personnel25
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Best Practice Tip:
Apply clause 7.4.4 to your in-house laundry!
Protocol – Page 6526
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Vertical Audit27
� Production Records, Recipe, Mixing Records
� Supplier (Goods Inwards Record, Delivery Dockets)
� Customer (Despatch Record, Invoices)
� Specification
� Supplier Approval Documents
Process Records & SOP’s
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� Process Records & SOP’s
� CCP Records & SOP’s
� Training Records
� Cleaning Records
� Test Results
� Preventive Maintenance Records
� Etc.
Recap28
þ Use decision tree to establish your areas + Appendix 2
þ Review your HACCP flow diagram (include areas identified)
þ Develop plans and schematic plans (include areas identified)
þ Consider new frequencies
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þ Consider new frequencies
þ Conduct risk assessments
þ Conduct a pre-audit
þ Conduct root cause analysis & take appropriate action
Thank You29
Thank you for your attention!
QS-Development - BRC for Food Safety Version 6
www.qsd.ie
NEWS: IFS Food Information Seminar30
IFS has gained worldwide recognition, therefore
food manufactures aiming to have long-term
business with retailers in continental Europe are
advised to seek certification to IFS Food Version 6.
QS-Development - BRC for Food Safety Version 6
QS-Development and the certification body DQS
are inviting the Irish food industry to this unique
IFS food information seminar.
For more information and bookings visit:
www.qsd.ie/ifs-food