'Foundation Degree (FdSc) in Food Manufacturing Management Essay\r'

'Introduction\r\n rail stress neutrals\r\n wherefore visit?\r\nThe intentions of this scrutinizeed account argon as follows:\r\n victimisation a recognized GMP stock(a) (UNIDO/BRC) assess and quantify the posture of the below counsel superior t stretch forthk that is in d sounding.\r\nRecommend, upon recap, st markgies for miscellaneament that buns be nurse to meet, and potenti whollyy exceed, the b vagabond hound retail pip a sortments.\r\n* Upon completion, accord the duty to tack attainable goals and objectives in differentiate to drive the blood forward. This is in an efficiency, harvestion and legal capacity.\r\nComp distributively indite\r\nShetland SeaFish (Hull) contain excoriati whizd trading in 1922 as a specialist manufacturer of rigid slant harvestings. The political variancey employs 50-60 cater on post and has a total of 80-100 employees firmnesss(a) through and through off the group. The group has trine factories. The early (a) two argon involved in prime emergenceing and lean do report in the Shetland isles. The social club supplies super market tells, discounters, fish wholesalers, arctic viands distri exceptors and diet for thought service companies. The chief(prenominal) market is the UK except forthwith the corporation similarly has a sm entirely export trade. Shetland SeaFish (Hull) specializeed has utilise a tightly containled debris of operational executions including a fully put subject HACCP frame and flavour manual.\r\n handicraft milieu\r\nThe diet pains is peerless on a dispirit floor pressure. The fishing in beat cleanry in feature is an atomic number 18a with its bear grouchy riddles which ca-ca a direct meeting on this party as fish is its primary raw clobber.\r\nOver the agone a couple of(prenominal) categorys, environmental concern over change magnitude fish germinates has contri thoed to sum upd governmental interdiction to manag e fishing quotas. Although this whitethorn be the case for the national fishing industry, the creation wide tweak (up until recently) has been on a steady rise. This political party sources raw flavorlesserial from worldwide locals ( dissolveicularly the Asiatic aras such(prenominal) as China and S bottom of the inningdinavian Seas) so the impact has been minimal.\r\nThe room in which the comp either sources fish whitethorn change in the future, as internet auctions argon on the view, and this makes the market much than than(prenominal) of a volatile entity as prices washstand fluctuate as nonwith standts dis be tenacio victimisations fishing procurement.\r\nThe other(a) chief(prenominal) occupation of engagement with the so chapeau diet industry is the strength of the study multiples over the manufacturers. The major supermarkets to whom most nutrient for thought manufacturers supply, aim to primary(prenominal)tain a continual gross profit bound whic h is typic e very(prenominal)y quite large. To reflect this, the multiples like to gag down on- be to the suppliers. Offers such as ‘ deprave superstar, get one melt’ be fuelled by the manufacturer, and come straight from their target line. By running a â€Å"BOGOF” offer, it is proceedively marketing the crop at half the unit of measurement price for the duration of the offer.\r\nOne supermarket that this comp either has dealt with as well deducts (on their own accord) a forget me drug price to go towards advertising and marketing. For example, a deduction of �10,000 faculty be deducted from an flyer to them for product, with the reasoning being that even if that tote up is non being put ond to now promote that particular product, just by advertising the stores in oecumenic, the incr backupd t eachy of customers prevailing through the store, should they say, increase gross gross revenue to the comp whatever’s product. This deduction from the story is imposed by the supermarket, and beca office you do non get along how a lot they argon issuelet to do this, it makes approaching for melody more grueling.\r\nCombine this with the fact that at both(prenominal) price criticism by the supermarket emptor’s, they demand higher timber products, for a reduction in unit price, depresses margins lower than ever.\r\nThe margin depression brings with it a decorate of enigmas. Because a company has to geld its costs to meet the price points per units, so as to maintain the business enterprise with the supermarket, it makes it for a business to remain as profitable as what it would like to be.\r\nA sm eacher margin agent that a company does non deliver the same summate of openhanded capital acquirable to it to make unavoidable re-investments which would wait on to procure more sales and increase throughput. In section four-spot of the overview, a detail study of this is reaso ned in recounting to an OEE study on one of the factories lines.\r\n in that respect be several(prenominal)(prenominal)(prenominal) expert resolutions gettable which if purchased would go a foresighted authority to increase productivity. unfortunately at that go forth be several fiscal constraints which air barriers to the procurement of these technological advantages. A apprise discussion of ‘Chicken and Egg’ barriers is bely explained in section four of the overview.\r\nThe task lies in the fact that if a red-hot piece of equipment is use uped to continue, or to meliorate hightail it, accordingly the company does non suck enough liquid capital avai laboratoryle to be able to purchase it prohibitedright. This means that the company would overhear to investigate espousal facilities.\r\nThe occupation with this is that the company would like to set ab dis overfly a secured amount of business from one of, or a combination of customers, in o rder to dart on the take a chance of borrow large amounts of bills. The reason for this is that a company has to account for a pay post flowing into their costing to cover borrowing and interest as well as machine depreciation.\r\nWith conened product posture tenures, the guarantee of keep business for this period is non in that respect, bottle uping the business from wanting to take a lay on the line of this magnitude. unconstipatedtu all toldy a company has to ‘bite the bullet’ and take a take a chance in order to increase turnover and throughput.\r\nSmaller margins similarly mean that there whitethorn not be enough of an increase in net profits to cover lag requirements. Each year there is a general rung appraisal to discuss the cost of pursues and conditions. If the company is decrease in its profit capacity, accordingly this slew is very much cartridge clips relayed onto the workforce.\r\nf the company has fall available finances so(pren ominal) money is not possible to give staves the annual increase in wages or to be able to invest in communal facilities.\r\nThis has a knock on do on mental faculty esprit de corps and motivation if the annual increase is postponed or if it has to be t oil colorettecelled. It manifests itself in or so case-by-cases in a revenge motivation mentality. As the unmarrieds belief aggrieved because the company rear endnon accompany with what the workers feel is a basic right, thus they may wish to ‘get back’ at the company.\r\nAt best this may just be by lessen their amount and persona of work, therefore their faithfulness is affected. At worst, it could be resignation, dissention or even around outrank of industrial sabotage.\r\nWithout the increase in wages rates it too lessens the difference amidst that and what the government sets as the national minimum wage. This poses a difficulty in relation to retaining, and gaining sunrise(prenominal) employees .\r\nAt one point, on the job(p) in a mill used to attract a premium, exactly over time that has decrease to the point to where wage aims amongst scab workers and pulverisation workers argon well-nigh the same.\r\nWith the current work ethos among sore employees (particularly young community) the predicament of where would ‘I’ like to work arises. every a ( ordinarily) smelly, transubstantiation work strategy, to a great extent work inducing grind, or a shop, where they brook go straight out from without having to go home for a rain shower and change, is less hard work and usually has a set nine until tailfin work pattern. For the same, or similar, wage, most people appear to want to work in a shop.\r\nThis dis bids a distinct shift from employment curves from primary or subaltern employment to a majority of employment in the tertiary, or services, sector.\r\nIf a company has a high turn-over of staff, wherefore chiefly the quality of staffs decre ases. This may then affect mathematical product output and efficiencies.\r\nOne way that this can be combated is though an increase in staff reading. This not nevertheless acts to both increase staff quality, precisely it withal processs to im sustain the soulfulnesss’ farm out mirth. This is through change magnitude competency, increased knowledge (i.e. qualification an individual more multi-skilled) and the feeling that they be not in a ‘ blind alley’ job.\r\nIn the industry sector to which this company falls, there is an increased amount of governmental grants available for staff readiness create mentallys.\r\ninside this grind, all of the employees of maiden tier direct pack all been through NVQ level 2 re turnout in victuals hygienics and plentyling. increaseion supervisors fork over standard additional training to NVQ level three in this ara. at that stead is in any case a range of other courses that be being studied that b e part funded, or reimbursed by, governmental policies.\r\nIt is go through that there be some relatively easy shipway to increase the efficiency and line throughputs of issue. Unfortunately limiting factors come into play to inhibit potential growth as long as margins be squeezed smaller and smaller.\r\nThis is a self perpetuating cycle. If leaseed to make a runty bit more profit then this can be channelled back into the business to increase production efficiency and general turnover make the business more successful.\r\nLegal Issues\r\nthither is a confused mine field of getula that comes into play when dealing with a f ar unit operation. thither is a whole superfluity of acts and regulations which assistant to fake the aliment industry which helps to protect the consumer from dubious practices and ensure that the last(a) product that is consumed is of the expect substance, genius and quality demanded.\r\nthither ar several levels of legislation:\r\n* co mports, which atomic number 18 statutes passed down by parliament.\r\n* Regulations †which be do low specific acts\r\n* E.C. directives †which are passed down from the E.E.C.\r\nThe nutrition condom enforcement plazars move over mixed enforcement powers which enable them to ensure that all of the legislation is decently adhered to. These can be servicing notices, sampling and seizing nutritionstuffs, and withal to instigate criminal proceedings if an of contend is do.\r\nThe main legislation affecting this business are to be listed as succeeding(a);\r\n nutrient sanctuary puzzle out, 1990\r\nThis act is in relation to the sale of food for pieces consumption and is applicable to all food expound.\r\nThis act makes it an offence to:\r\n* Render food injurious to health\r\n* Sale or possession of food injurious to health, or that is unfit for, or is polluted.\r\n* Sale of food that is not of the correct nature, substance and quality demanded by the consum er.\r\n* Give any phony or misleading descriptions.\r\nThe Food exposit (Registration) Regulations, 1991 (SI nary(prenominal) 2825) revise 1997\r\nThis regulation requires all food premises to register with the local, or port authority, in the field of view that they are laid. Every registration authority essentialinessiness honor a register, which can be accessed by the public for inspection.\r\nFood sentry duty device (General Food hygiene) Regulation, 1995 (SI. none 1763)\r\nThis act translates general requirements for all food handlers and premises (with specific requirements for preparation heavenss, moveable and temp. premises, transport, equipment and the like) to be unbroken clean, accelerate cleanup spot, and prevent the accumulation of dirt. It overly specifies a requirement for all food premises to advert all travel in the business that is critical to food safety, and to background these finds.\r\nThe Food Safety (Temperature chastens) Regulat ions, 1995 (SI. no 2200)\r\nThis de terminationines any matter involving a risk of infection to food safety, in relation to the nature of the food, manner in which it is handled and packed, and processes and conditions under which it has been displayed or stored. no.person should keep food that is likely to support the growth of morbific bacteria or the accumulation of their toxins.\r\nProducts of animal Origin (Import and Export) Regulations, 1996\r\nThese regulations govern the origins of animal foodstuffs from countries immaterial the EEC. Since 1993, foodstuffs imported from other members of the EEC are not liable for inspection callable to the rough border policy, whole they are still subject to the Food Safety Act 1990.\r\nFood Labelling Regulations 1996 (SI. No. 1499)\r\nThese require most foodstuffs that are to be exchange for human consumption be labeled with:\r\n* The make water of the food.\r\n* List of ingredients (Quantifying ingredients mentioned in the nam e of the food).\r\n* Best ahead dates, which indicate minimum dur force or perish ability of the food in relation to microbic or product degradation beyond being fit for human consumption.\r\n* whatever specific storage conditions infallible.\r\n* Name and underwrite of the manufacturer\r\nThe Quick-Frozen Foodstuffs Regulations, 1990 (SI. No. 2615) amended 1994\r\nFood that has undergone quick-freezing (i.e. whereby the zone of level best crystallization as rapidly as possible) should be labelled as such. It moldiness be suitably packaged so as to protect it from microbial and other befoulment and as well to protect from de-hydration.\r\nMust be labelled with:\r\n* BBE\r\n* remembering requirements including temps.\r\n* Batch abduce\r\n* A stimulate message not to refreeze after defrosting.\r\nthither are similarly some specific legislation relating to food poisoning:\r\n mankind wellness (Control of Disease) Act 1994\r\nThe Public Health (Infectious Diseases) Regulati ons, 1988 (SI. No. 1546)\r\n discipline Health Service (Amendment) Act 1986\r\nThe depicted object Health Service (Food Premises) Regulations, 1987 (SI. No. 18)\r\nThe Public Health Laboratory Service (PHLS)\r\nThese pieces of legislation relate to reports of incidences of food poisoning and food borne illness. It empowers incumbents to investigate food premises on the radix of risk to increased infection, and to rate the source of food poisoning illnesses.\r\n transgress to food related issues there are likewise a number of other pieces of legislation that apply to most businesses. These are:\r\nHealth & Safety\r\nThe Health and Safety at piddle Act 1974\r\nThe Control of Substances Hazardous to Health Regulations, 1994 (SI. No. 3246)\r\nThe Reporting of Injuries, Diseases and Dangerous Occurrences Regulation, 1985 (SI. No. 2023)\r\nThe electricity at defecate Regulations, 1989 (SI. No. 635)\r\nThe counsel of Health and Safety at work out Regulations, 1992 (SI. No. 2 051)\r\nThe Workplace (Health, Safety and Welfare) Regulations, 1992 (SI. No. 3004)\r\nThe Personal antifertility Equipment at Work Regulations, 1992 (SI. No. 2966)\r\nThe Manual giftling operations Regulations, 1992 (SI. No. 2793)\r\nall(a) of these laws are in relation to retentivity equipment in upright order; proffer all PPE, also in good order, and to report all accidents and health check chores caused by/ at work.\r\nThere are some new environmental legislation in relation to scratch off water and effluent, and also the climate change levy.\r\nThere are also raving mad land fill laws (After B.S.E. and Foot and rima oris no food devours can be get ahead processed into animal feeds)\r\nIt is clear that there are a dance orchestra of laws that help to keep the consumer, and employees safe, both in relation to food safety and own(prenominal) safety. In order to stick with with all of these laws, and check with the company’s residency to these, the office of fair trading and the environmental health office canvas the milling machinery on a regular basis.\r\n portion\r\n2\r\n name Findings\r\nSummations on Audit checklists\r\n subsection by section review\r\nHACCP System:\r\nThe company has a very detailed and comprehensive HACCP corpse spare-time activity the Codex principles and establish on risk assessment for each product type.\r\nThe latest decree is June 2002. The HACCP documentation accepts Introduction (Intro, police squad up, product description, intended use, flow diagram, and hinderance of flow, controls and hazards), subroutine flow (product, production process), Hazards, Hazard abridgment and Hygiene controls.\r\nThe site technical theatre director who is qualified in advance food hygiene leads the HACCP group. The other HACCP team members let in the production manager, financial director, business consultant, Q.A. supervisor and H&S officer. They have all received training in HACCP principles.\r\nEight CC P’s have been set and all the way marked roughly the site. These intromit; R.M. intake, band saw room, product storage, besidesance storage, coatings, sauce fashioning, sauce buggies, sauce atte transmit and metal detection.\r\nShetland SeaFish (in conjunction with Cravenglow consultant limited) has produced a handbook for employees entitled â€Å"Understanding HACCP and the British Retail Consortium prime(prenominal) submit”. This book was issued to all staff originally going through their first successful BRC audited account, and is issued to new staff during induction. The Handbook explains; HACCP terms and working practices, details the eight CCP’s, How to control potential Hazards, How HACCP works, Different types of Hazard, other of import HACCP tuition and an introduction to the BRC standard\r\nQuality prudence System:\r\nThe site operations/quality manual has been fully implemented and indexed in the latest revision (Revision 4 October 200 2) to the BRC technical standard version three.\r\nPolicies and procedures reference to the HACCP manual and currently cover all of the identified critical controls.\r\nEach working area has its own handbook that take ons some or all of the following:\r\n pulverization modify procedures\r\nTechnical terms\r\nKey staff\r\nSafe working practices\r\n mill procedures\r\nQA procedures applicable to the area.\r\nA specifications file keep by the company has a curriculum of inseparable audits that cover the entire quality system twice per year.\r\nThe handling of complaints is the responsibleness of the Technical manager. Complaints are referenced individually, by customer, and complaint type. Corrective actions arising from complaints are studyed.\r\nAn okay supplier list is in operation, deliveries assessed at intake, and supplier performance reviewed quarterly. One of the secernate findings of this audit has been that although the supplier audit plans clearly delimit and laid out, it has not been adhered to. This take away rectifying by the time of the next audit.\r\n grind Environmental Standards:\r\nThe factory is well find just off the main itinerary into Hull, and has a logical process flow.\r\nThe buildings are well constructed. Walls panelled with false jacket and facile concrete floors.\r\nEquipment is industry standard and is be well maintained. There is a think maintenance system administered by a well-resourced engineering department.\r\n mental faculty changing facilities are provided by intermit storage of work cave in and personnel wear with staff locker rooms situated well away from production. Work raiment situated in changing facilities on the influence to the production facility.\r\nA dedicated shadow hygiene crew operate a comprehensive cleanup spot programme, verified victimisation bioluminescence ATP swabs. This form of assessment is under utilised. By conducting more swabs, a more indicative trend analysis can be compi led. This system could also be broad to be hand swabbing, so as to hazard the effectualness of the staffs hand wash.\r\nA comprehensive curse control contract is in place with â€Å"Rentokil” and no infestation reported. The except addition to this politics would be to unveil catch tray analysis. This is not make at present, although Rentokil have been asked to provide a quote for the service. The reason that catch tray analysis is so important is that various indicator species of insect may help to unwrap a particular problem at bottom the factory. other option is that the restrainer is a qualified entomologist. The adumbrateion has been make that they complete the catch tray analysis on behalf of the company.\r\nTransport and brag removal are both contracted out services.\r\nProduct Control:\r\nThere is a product maturatement procedure detailing the process timbers and documentation held for customer determined development work. Development work is mainl y restricted to crumbs, batters and sauces and as such, the suppliers of these materials carry out a lot of the work.\r\nProduct is analysed on line hourly by clever QC staff\r\nExternal chemical and microbiological analyses are carried out at a UKAS trustworthy external laboratory. The result turn about is typically ten daylights. There is an investigation into the possibility of bringing the microbiological interrogation into a feasible in-house solution. The testing procedures preferred are the rapid methods that are now available on the market. These endure for rapid figuring and identification in unprecedented speeds compared to handed-down plating methods. Because of the simplicity of the tests, it subverts the degrees of error that cogency be entertained in doddering style methods, and also it helps to simplify the lab quality manual. alone of these rapid methods are AOAC accredited methods and are thus suited for ISO 17025 standards, which is a pre-requisite fo r the accreditation edicts stated for BRC compliance.\r\nProducts coded to allow stock rotation, and on-site stock levels unbroken to a minimum. The cold store has the capacity for near 600 pallets, which are on a sedate racking system.\r\nMetal detection is carried out on all products at 3.5mm non-fe and 3.5mm fe. enactment is on the way to incorporate testing victimisation S. Steel rods as well, victimisation the same sensitivity levels.\r\nProduct is released based on on-line QC testing. A non-conformance procedure is used to prevent the hit of non-conforming product and its restriction to quarantine.\r\nProcess Control:\r\nControl of sauce cooking and processing is near monitored by QC and thermographs are in place to tramp sauce cooking profiles.\r\nQC also regularly verifies process parameters and freezer temperatures. persisting quantity control monitor equipment is in place on the coated fish line.\r\nCheck-weigh systems are adjust at the start of each day follow ing a detailed calibration procedure.\r\nHourly QC checks and insouciant taste panels verify process parameters and specifications requirements have been fulfilled and all measuring equipment is calibrated at appropriated frequencies.\r\nA small amount of kosher product is processed on site and the delivery processing and despatch of kosher materials is closely monitored.\r\nPersonnel:\r\nStaffs train to NVQ levels 1 and 2 in hygiene and safe product handling by external consultants. Plans are in place to introduce an in-house training scheme. The Q.A. supervisor holds a CIEH certificate of Advanced Food Hygiene. one time they complete the CIEH professional trainers’ certificate, it will allow them to train new staffs, and re-iterate to current, basic food hygiene and H&S.\r\nHygiene rules are also available in the staff handbook, given at induction.\r\n instalment complicates hygiene and H&S requirements, fire drill procedures including a trance of the facility (highlighting emergency exits), company objectives and the review of the individual’s accountability level.\r\nStaff and visitors complete a basic medical questionnaire before entering the factory.\r\nProtective clothing provided and laundered by â€Å"Brooks” based in Hull and all specialising in make clean of food industry clothing.\r\nSupervisory staff and line attractions trained to NVQ levels 3. detailed training immortalizes are in place, but not review on a frequent basis.\r\nSection\r\n3\r\n service strategy\r\npassports on enhancement\r\nWhy did it fail? What can be done?\r\nThe overall result of this audit is promising. The main sections that are in need of make betterment are the cleanup spot and management systems.\r\nWith regards to the change controls one of the biggest deficiencies is that there were no nonchalant cleaning logs in place at the time of the audit. These are necessary to verify that all of the pieces of equipment that has been us ed during the course of the production shift have been cleaned effectively. This should also incorporate a list of equipment that needfully hebdomadal or monthly cleaning, similar to the engineers’ protective(p) maintenance system.\r\nProvisions are in place to indicate cleaning frequency, but by combining this with a insouciant cleaning log a system of records can be obtained to help with any ‘Due Diligence’ defences that baron need to be called into play. The preventative step to reduce the microbial and soil loads at bottom the factory are the cleaning schedules, but the due diligence defence are the daily logs. These are a record confirmation that the schedule has been implemented, and also provides accountability of who conducted the particular action that faculty be in question. It also helps the management team to assess the manning levels required for a particular cleaning regime.\r\nBy combining these logs with an effective utilisation of the Ligh tning ATP hygiene verification system it would be possible to more accurately monitor the effectiveness of the cleaning systems that are in place. At present the unit is not used at levels that are going to supply the monitoring team with a set of results that are statistically important. By increasing the levels of testing with the unit, a better picture of cleanliness levels can be obtained by using the trend analysis software to scrutinize past results and to predict problems that might occur in the future.\r\nThis system could also be extended to apply to incorporate hand washing checks. This could be done on a random set of checks passim the week. It might be possible to correlate this to the anticipate and true bacterial soap consumption rates to see if there is a relationship. This might be an extra way to monitor the effectiveness of the staff in the own personalized hygiene in relation to hand washing.\r\nThe engineers need to keep an inventory of move as a kettle o f fish is carried out so that all pieces are accounted for upon completion so as to eliminate the possible physical taint problem, or at least to draw if there is one.\r\nA number of hose pipings were spy some the factory, liberally strewn on the floor. This is not bad GMP; it also creates an idea of untidiness and not caring for not only if visitors, but also to other staff. Perhaps the buying or some hose whirl storage units. If these hoses were unplowed on one of these units, it would automatically reel in and is then kept neatly on the wall, off the floor and out of the way of people walking close to the factory.\r\nDuring the course of the audit the food run through pass crosswise was left open. This leaves the door open to many potential problems. The first is that it has a potential to attract pests. By departure the wipe doors open is may provides a food source for advantageous varment.\r\nIt was observed that there were some birds on the fence which might have been attracted by the oddment surrounding the skip. To eliminate this problem locution of a reaching handle for the skip door should be made.\r\nBy care the skip door closed it prevents vermin from entering the skip to scavenge for food. With the skip door closed, thus stopping pests from gaining a free food store, the area around the skip must be kept clear also; otherwise keeping the door closed is a superfluous effort.\r\nThis area not only necessarily to be swept, but also cleaned down with a purifying to emulsify the butterball residue left from the batter scraps. This would also help to make the area safer for the employees as it would make the area left flat to causing slippages, and this is especially important as there is a small set of steps out there.\r\nThere is no provision for persons to wash their hands upon re-entering the factory after going to the food skip. There person would have to go to the river basins away(p) the packaging area. A small basin or alc ohol station should be installed to prevent this.\r\nThe main body of the factory was in very good condition. There were a few incidences that need to be rectified in order to amend the grade.\r\nAround the sauce making area, the ceiling tiles above them had some signs of redact growth. This is an meter reading that the external respiration is perhaps in fitting for that area. around form of steam stock unit might need to be investigated in that area. In the short term, regular cleaning with a sterilizer (with some form of mould growth inhibitor) would suffice, but this would only deal with the symptoms, and not deal with the highroad cause.\r\nThe sauce fomenters in this area are in need of recovering. The motors on the agitators have some small areas of paint flaking from them. Even though the paint is blue in colour, it provides a potential physical contamination problem. This needs to be tackled in several ways.\r\nThe first and easiest to do is to recover the motors. Th e motors can be covered with a innocuous steel covering which would prevent both paint flakes falling into the sauce, but also dirt accumulation on the motor.\r\nAnother method is to use an alternative agitator motor. There are several on the market, and several of these are not attach directly above the sauce making kettles.\r\nThere are also some other methods for sauce production, that if increased production were to be required, then they should defiantly be investigated.\r\nAnother area in the factory that could advance from additional filiation/ventilation is directly surrounding the coating line. When the frier is producing breaded products, then the first stage crumb, which is a fine crumb, causes a lot of dust to be blown in the air. This causes excessive dust accumulation on the pipe works above the pullet line. This needs additional cleaning to remove the dust in this area. Perhaps a form of lineage system should be investigated in this area.\r\nAs a minor point, t here was also a small pussycat of water surrounding the con-air compressor units. This implies that the floor does not bevel in the right direction. again this is a location that has a long term objective, but also has a short term measure.\r\nThe long term goal is to re-lay the floor in that area to make the floor slope in the right direction (i.e. from the wall to the drain). The short term solution is to have the cleaners regularly squeegee the floor of water.\r\n stand up water is a particular problem in that it provides clear breeding argument for Listeria spp. Bacteria. Listeria is a food borne bacteria that is course found in the environment. By providing getupty-cats of standing water, it magnifies the problem and opens the potential for increased incidences of Listeria monocytogenes poisoning.\r\nIt is a strange practice that although there are manager and team leader meetings on a regular basis, there were no supervisor meetings held. This is a gross deficiency, n ot for GMP, but for the leave out of confabulational strokes that are missed from these meetings.\r\nBy conducting these meetings a intercourse can be maintained between the higher levels of management and the junior levels. During these sessions company objectives can be relayed, problems considered, and grievances examined.\r\nIt is also an excellent opportunity to provide motivation to the staff and to keep them apprised of important happenings in spite of appearance the company, such as potential sales, production turnover, NPD and the direction of the company. These meeting should be implemented effectively straightawayly. If not in their own right, then try combining the team leader meetings. This may pose a problem with truthful communion if the team leadership feel inhibited by the strawman of the supervisors, especially if they have any grievances with them.\r\nThe carelessness of the supervisor meetings exacerbates the next point. That is the cross communication of ideas and instructions between departments. This point is discussed in more detail in the endorse overview of the audit.\r\nThe job descriptions that are in place for the rudimentary positions indoors the factory are deficient in the totality. I would suggest a review of these be taken with the specific aim to include the individuals’ main duties and responsibilities, full accountability, and any health and safety requirements that are obligatory to know.\r\nBy providing a comprehensive description it helps the individual to identify their own progress against what is expected of them. It would also help to identify any training needs by comparing what the individuals’ tangible abilities to what is required for that position. During an appraisal a gauge of competency can be made against the standard and a measure of feedback can be relayed to the person.\r\nThis also ties into the fact that no records are kept of personal record reviews. These need to be conduct ed on a regular occasion, and if they are being conducted at the moment, then they need to be recorded.\r\nThere are some clear objectives that have been identified and now need to be applied and rectified to improve the factory as a whole.\r\nSection\r\n4\r\nConclusions\r\nOverview of progression stratagems\r\nStep by step guide\r\nStructure and Fabric\r\n* Hand washing basin/ alcohol station to be installed by exit to food skip.\r\n* Foods skip needs to be looked at and a handle constructed to enable the lid to be closed.\r\n* Sauce kettles needs to be looked at for possible installation of extraction units.\r\n* Sauce agitator motors needs to be covered to prevent paint flaking into product.\r\n* water pipes to be placed into self reeling units.\r\n* jackpot of water needs investigating around con-air units. Floor needs re-laying in that area.\r\n* break up accumulation above fryer area. spare extraction needed.\r\nPest prevention\r\n* palette shed door needs to be kept close d. Pallets stored away from walls in storage.\r\n* more or less drain covers missing and needs replacing.\r\n* thumb tray analysis needs to be done.\r\n modify systems\r\n* Daily cleaning logs introduced.\r\n* Engineers inventory of parts during a repair to prevent contamination.\r\n* impressive utilisation, and expansion, of ATP hygiene monitoring system.\r\nManagement Controls\r\n* Introduction of supervisor meetings.\r\n* Additional training to supplement and increase knowledge of GMP systems, Food hygiene and legislation.\r\n* suss out of job descriptions.\r\n* videotape employee appraisals.\r\nSection\r\n5\r\nReferences\r\nBackground / further reading.\r\nIncluding bibliography\r\nHygiene for Management, Sprenger. R. A. 1998 (8th Ed)\r\nCleaning, Dillion M, et al\r\nInspirational Supervisor, Shaw J. 1999\r\nFdSc Food manufacture management GMP Course work notes, Dillion M. 2002\r\nLog book\r\n&\r\nOverviews\r\nOverviews\r\n tell 1: Basic findings from two sections of t he manual.\r\nSection 1 †Structure and Fabrication\r\nThe factory has a logical process flow and the buildings are of sound construction. All internal factory wall surfaces are panelled with a lowered false ceiling and smooth resin floors. Equipment is industrial food grade standard and appears to be well maintained. A preventative planned maintenance system is in operation and resourced by a competent engineering department. The work wear is situated in a separate clean changing area immediate on entrance to the production area. The pest control is out-sourced to Rentokil (initial services) with no signs of infestation problems to report.\r\nOBS 1: The floor is made of an impervious material and when combinations of two immiscible liquids (such as oil and water) mix, it causes some sections of the floor around the fryer area are slippery.\r\npassport †Review the cleaning schedule for this area to include a protocol stating that the floor in that area is to be cleaned as o ften as required throughout the production day, in addition to the usual plan cleans. Another suggestion would be to use a floor covering/mat to make the area more non-slip.\r\nTimescale †30days\r\nOBS 2: There was a small pool of standing water around the con-air units during production.\r\nRecommendation †The long-term goal would be to re-lay/repair that section of floor to provide an adequate slope to provide water run-off into the drainage channels. Action to be taken place in the mean while would be to revise the cleaning schedule to include that the area is to be cleared as often as required throughout the production day.\r\nTimescale †90 days\r\nOBS 3: There was no steam extraction above the sauce making kettles broad rise to N/C1.\r\nN/C1: state was noted by observation and noted, audit checklist ref: GMP Section 1 -ref 1.8.2, that there was the beginnings of mould build up on the ceiling tiles above the sauce kettles.\r\nRecommendation †Investigate t he possible methods of fume extraction best suited to the needs of the task. potential installation of an extractor cowling. Action that can be introduced quickly is that a revision of the cleaning schedule to include periodical/fortnightly/ or as required cleaning to be undertaken in that area using a detergent with mould growth inhibitor.\r\nTimescale †90days\r\nSection 2 †Storage Facilities\r\nStorage or R.M, WIP, finished goods, packaging and tainting elements are well segregated with observed codes of practice to prevent cross contamination. Products are coded to allow stock rotation on a FIFO basis and the stock levels that are kept on site are kept to a minimum. There are no contractual off-site storage facilities used. Products are released on the basis of on-line QC testing. Procedures are in place regarding damaged or crackive goods sequestration and disposal.\r\nOBS 1: Only visual checks are made of the contracted out logistics company’s vehicles.\r\nR ecommendation †Revise an audit schedule to visit their head office so as to not only audit the vehicles used for the transportation of goods, but also to review the company policies and procedures regarding GMP practices.\r\nTimescale †90days\r\n eccentric 2: Area to improve.\r\nThe area of great need is management control, especially in relation to motivation of staffs and inter-departmental communication. A super motivated workforce can increase the potential output efficiency greatly, without the need for pricey capital expenditure.\r\nâ€Å"Poor communication is the catalyst for future problems”\r\nJohn Shaw, Business consultant\r\nThe vast majority of problems within the workplace arise due to the lack of or inadequate communication between colleagues.\r\nAll members of the organisation must develop their verbal and written skills to allow for ease of dialogue between the two parties. lawful dialogue is essential for the pooling together of ideas and sugges tions that helps to minimise problems and help to achieve the company objectives.\r\nEmployees must be able to interpret management edicts and be able to pass on these instructions to other staffs clearly and in short in order to achieve confidential information performance.\r\nOne opinion that might be made is that the company’s nonpersonal uses of memos are substituting important meetings that would be held to discuss some of the key issues. By conducting regular meetings to open up a dialogue for discussion, it would help to eliminate any confusion that might have arisen because of their own interpretation of what is trying to be punctuate in the communiqu�.\r\nBy opening a dialogue between colleagues, it helps to make them feel a part of the team because they are being consulted and being offered to stress their opinions and grievances. During the meetings, it lets the individual know exactly what is being expected of them to do, with little chance for error . erstwhile the individual knows the parameters in which they are expected to perform, and then the individual has some attainable guidelines on how to conduct him or herself around the workplace.\r\n existence made part of a team is one essential tool in the motivation of staffs. By including their opinions within any debate, it helps to raise that person’s self-esteem. Once a person begins to become motivated, it often leads to greater job satisfaction.\r\nJob satisfaction is a combination of hard work and competence. Employees who reflect pride in their work are an infectious source of consumption to others. This can be seen again in persons whom take personal pride and lead by example.\r\nMotivation is a key component to modern businesses. Staffs should take every opportunity to motivate others constantly. One way to encourage your staff is to let them know what is required of them by defining the day’s objectives.\r\nUse of praise and encouragement inspire maxi mum performance from an individual from a few choice nomenclature or phrases.\r\nWhere an individual or team needs berating if they have made a mistake, remain calm and resolve the problem through constructive criticism. This is where the situation is given an explanation of what went wrong, gentle lecture to re-enforce the need that it does not re-occur, and gives further guidance on how it can be avoided in the future. It is imperative that if it is an individual involved, then take them to one side to discipline them. This way you are not undermining them and therefore their personal dignity is maintained.\r\nAnother critical instruction is not to overreact to minor problems. mischievous and unwarranted criticism is harmful to team spirit and can easily sweep across a work force.\r\nIt is also a good idea to be clear to reasonable grievances that they might have and suggestions that they might make.\r\nMotivation encourages individuals and teams to continually achieve the co mpany’s goals through sustained decimal point performance.\r\nPart 3 Cleaning and the practice of law\r\nCleaning plays a fundamental part of food hygiene. It is pivotal in preventing contamination of both microbiological and chemical, but it also helps to make the indicator signs of pest infestation easier to spot.\r\nAll cleaning comprises of four factors:\r\n* Heat\r\n* automatonlike energy\r\n* chemical energy\r\n* turn over time\r\nCleaning is usually a five stage process (although not exclusively).\r\n1) Pre-clean\r\n2) Main clean\r\n3) Rinse\r\n4) scrub\r\n5) Final rinse\r\n6) Drying\r\nThe relative energy and time components of a cleaning programme can differ greatly. This is all dependants on the load of soil age, the chemical properties of the cleaning agent, and the surface to be cleaned. Staffs should receive clear concise instruction on how to correctly conduct the cleaning schedule.\r\nThe chemicals used within this factory are as follows:\r\nChemical\r\n Action\r\nFatsolve\r\nbed wetter degreasing detergent\r\n decolorize\r\nHypochlorite based disinfectant\r\nSparkle\r\nSurfactant degreasing detergent\r\nAcid foam\r\n acidulous de-scaler\r\nCaustic floor cleaner\r\n alcalescent (NaOH) floor cleaner\r\nCaustic pearls\r\n alcalescent (NaOH) fryer cleaner\r\nTego 2001\r\nBiocidal disinfectant/detergent combination\r\nAll staffs that will be handling these products for use in hygiene must receive full training and monitored for competency and efficiency. All of these products must comply with the Health and Safety at Work Act 1974 to protect the employee whom is to be using these chemicals.\r\nThis Act states specific legislation to include:\r\nThe Control of Substances Hazardous to Health Regs, 1994 (SI. 1994 No. 3246) (COSHH)\r\nThese regulations require employers to assess the hazards and provide sufficient controls. Implementation is by means of risk assessment. COSHH is concerned with chemicals that can be sort out as toxic, harm ful, corrosive or irritant.\r\nAll of the products used within the body of the factory are supplied with all COSHH safety sheets and are filed in the technical department. Each of these products is mentioned in the company HACCP plan to include the risk assessment of these products.\r\nChemicals (Hazards, Information & Packaging) Regs, 1993 (CHIP)\r\nAgain, this states that all chemicals sold must be supplied with a COSHH safety sheet provided for the purchaser by the supplier. This must include detailed information about the product, its hazard classification under CHIP regulations. It is also prohibited to pour out harmful chemicals into unmarked containers.\r\nPersonal Protective Equipment (PPE) at work Regs, 1992\r\nThese regulations enforce the employer to provide all necessary PPE required for a specific task so as to minimise the health and safety risks that the employees might be subjected to.\r\nThere are several good reasons why effective cleaning is so important besi des those mentioned anterior:\r\n* It creates a good visual stamp for both workers and visitors alike giving a sense that the business cares.\r\n* Helps to maximise the efficiency and costing of several types of products. For example, if a sauce is left to build up deposits, then it would restrict the diameter of the pipe work, making the motor have to run harder to tenderness product through, thus reducing the biography of that component. Its also helps to reduce wastege\r\n* Legal obligations.\r\nIt is that final exam point which needs further explaining.\r\nThe food safety Act, 1990\r\nThis law makes it an offence to contaminate food so that it would be indefensible to expect it to be used for human consumption in its current state. It also states that a food owner and staffs must identify all steps that are critical to food safety and minimise those risks.\r\nThis is further backed up by the\r\nFood Safety (GFH) Regs, 1995\r\nThis states:\r\n* Premises must be kept clean, designed to facilitate cleaning, and to protect against the accumulation of dirt.\r\n* Make it a requirement for all food business proprietors to identify any step in activities of the business which is critical to food safety, and to introduce restrictive controls at those points identified.\r\nThis law allows an enforcement officer to raise a non-conformance on the actual presence of dirt, and does not have to prove that that soilage poses a risk to health\r\nThere is a clear legal and virtuous obligation that wherever there is a risk to food, a business proprietor must ensure that the working premises are kept clean so as to minimise the risks to public health. These responsibilities must be stressed to all employees not only in their induction period, but also sporadically throughout their employment.\r\nPart 4: PEST in relation to OEE\r\nDuring the course of this audit, an OEE analysis was conducted on one of the production lines (See OEE exercise workbook). The aim of GMP is to improve the manufacturing performance, and by using OEE calculations it is possible to gain a quantifiable index of performance. Using the precepts behind GMP it is possible to identify areas that could benefit from avail so as to improve production performance.\r\nThe identification of the â€Å"seven wastes” which are the non-value added and also the value added sections of a production period are vital. It is the main objective to reduce the first, and increase the latter.\r\nWith regards to the production run that was studied several strategies can be entertained to help to minimise waste due to the above mentioned wastes. Firstly, fish cakes are products that produce only small amounts of waste due to the fact that defects can often be re-worked during the same production run. speck cores can be removed from the line by operatives and then deposited back in the koppens former to be re-moulded into another cake.\r\n reduce the throughput can often help reduce the wi pe outs levels. Running at just a few strokes under the maximum for the line might make it more cost effective to reduce the throughput by a minimal amount in order to dramatically decrease the amount of reject product. By doing this the ‘right first time’ figure could increase to raise overall production efficiency.\r\nIf speed is the overriding factor, i.e. the scurrying the speed, the higher the defect rate, then just by reducing the stroke rate of the machine, the amount of over-processing required would be reduced. If besides speed were not the decisive factor, then an investigation of the machines capabilities would have to be reviewed, and if it cannot be removed, then do you accept this defect level caused by the machine, or do you evaluate the possibility of purchasing a more efficient piece of kit?\r\nWith regards to the machine that is in place, the Koppens former is most 10-15yrs old and forms cakes by using hydraulic cups and a forming plate. Over the ye ars the maximum output of the machine has dropped by approximately 25% from the max of 40s/m to now 30s/m.\r\nWould it be better to buy a new piece of kit. Perhaps the purchasing an AEW forming machine? Unfortunately these are costly pieces of kit. Costing in the range of �250K. This is a large prohibiting factor in an SME of the size of it of the company in question, with their limited financial resources. In order to justify a capital expenditure of that magnitude, a significant order would have to be procured to allow for the required payback period to make it a cost effective purchase.\r\nIt is almost chicken and egg scenario. With a new piece of machinery of this nature the potential for increased throughput of not only this line, but also of others would rise significantly, but monies or orders to cover payback periods would have to be secured before capital expenditure is considered.\r\nIt is a difficult political climate with retail customers at present. More and more of the major multiples only issue contracts for periods of usually a year (although there has recently been a downwardly trend to decrease these to six monthly). So a guarantee off continued business is not certain, which prohibits the purchase of the new machinery.\r\nThe small margins also affect the staff efficiency and remembering (thus quality). Because margins are tight, only a small amount on the top of national minimum wage can be applied. This can limit not only the response to job advertisements, but also with staff retention and loyalty. With a higher staff turnover, the quality of staffs employed often reduces, thus affecting the throughputs and efficiencies of the lines.\r\nThis interplay of factors is what has to be investigated further upon before resolutions can be found. Identification is just the first step in an overall improvement plan.\r\nAppendix 1:\r\nSummary Sheets\r\nGMP Audit Material\r\nEnclosed in this pamphlet are copies of the audit checklists that you can use to audit your site against each element of GMP.\r\nYou should aim to audit 2 elements of the standard each week and use the techniques discussed in week 1 on problem solving to objectively assess each element of the standard.\r\nIf you wish to discuss any elements in more detail then contact one of the tutors on the course who will be able to help you clarify any problems or issues that you may have.\r\nIMPORTANT\r\nYou will need to feign the food safety and hygiene audit assessment form each week, as you will need to use this to resume for each assignment.\r\nUsing the Sample legal opinion Forms for the 10 sections of Good Manufacturing Practice identify:\r\n1. Areas of Strength and Weakness for the GMP sections for your own be or operation, using the checklists provided.\r\n2. The causes of problems which are intrinsical with the areas of weakness\r\n3. The barriers and aids which will effect the improvement process\r\n4. Prioritise the actions needed to impr ove your Good Manufacturing Practice needs, using the assessment forms, which should be included within your weekly assignment.\r\nA razing system has been given on each checklist. You may use this grading system to help you to assess your factory, but feel free to modify this. If you do modify the system then you should explain, quite clearly, how the grading or scoring system is used.\r\nKey to the ABCD grading system for assessing the sections and elements of the GMP standard:\r\ncategory A Excellent wads 50 points. path A scored when there are no safety problems or issues. Requires no further action.\r\nGrade B Satisfactory tons 30 points. Actionable within defined timescale as agreed at audit.\r\nGrade C Major Scores 10 points. Actionable within one working week.\r\nGrade D Critical Scores 0 points. A Grade D is automatically awarded when a critical safety issue is identified, and is actionable immediately.\r\n'