Transcript PREVENTIVE MAINTENANCE: HACCP PREREQUISITE

Building Preventive Maintenance
Programs to Save Money and
Enhance Efficiencies
Richard F. Stier
Consulting Food Scientist
Sonoma, CA
[email protected]
COPYRIGHT RICHARD F. STIER 2011
PREVENTIVE MAINTENANCE
COMMON EXAMPLES
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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
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WHY YOU MAINTAIN
YOUR CAR
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PREVENTIVE MAINTENANCE
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
COPYRIGHT RICHARD F. STIER 2011
How To Make
Safe Food
SAFE FOOD
Total Management Commitment
HACCP
GMP/GAP
SANITATION
PRODUCT IDENTIFICATION & CODING,
RECALL & TRACEABILITY,
PREVENTIVE MAINTENANCE,
EDUCATION & TRAINING, AND OTHER
PREREQ PROGRAMS
COPYRIGHT RICHARD F. STIER 2011
Prerequisites and
FSSC 22000
8.6 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
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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
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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.
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HACCP PLAN DEVELOPMENT
FLOW CHART OPERATIONS
• Understand the process
• Means of conveyance & transfers
• Understand what needs to be maintained
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PREVENTIVE MAINTENANCE
BIOLOGICAL HAZARDS
• Loss of process control
• Contamination with foodborne pathogens
• Growth of foodborne pathogens
• Inability to properly monitor systems
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PREVENTIVE MAINTENANCE
TEMPERATURE CONTROL
• Malfunctioning temperature indicating or
temperature recording devices
• Belt Failures - Residence for continuous
processes shortened
• Pumps - Residence time reduced
• Refrigeration Failures
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PREVENTIVE MAINTENANCE
PACKAGING FAILURES
• Botulism in canned salmon (early 1980’s)
• Seamer adjustment failures (post-process
contamination)
• Sealer failures
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FOOD PLANT CHEMICALS
• Food additives
– Vitamins
– Sulfites
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Lubricants
Sanitizers
Cleaners
Antimicrobials
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PREVENTIVE MAINTENANCE
CHEMICAL HAZARDS
• Improper lubrication (excessive)
• Cleaners
• Failure to use food-grade/approved
materials
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PREVENTIVE MAINTENANCE
PHYSICAL HAZARDS
• Missing bolts
• Worn belts
• Metal to metal contact
• Broken blades, choppers, etc.
• Glass windows
• Protected bulbs
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PREVENTIVE MAINTENANCE
PHYSICAL HAZARDS
• Metal detectors improperly maintained or
calibrated
• Can or glass washers
• Buildings not maintained (rust, flaking
paint)
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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
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INVENTORY &
UNDERSTAND EQUIPMENT
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Process Flow Charts
Potential for Hazards
Units Essential to Food Safety
Equipment Setup Properly; Example,
Motors over processing lines
• Accessibility
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DEVELOP SOP’S for
INSPECTION & MAINTENANCE
• Work with Suppliers:
– Operating Manuals
– Training
• Inspections - Routine & Detailed
• Write Protocols - Date & Sign Off
• Place in a Manual
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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
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DATEBASES: WHY??
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Organization
Stronger prerequisite programs
Reduced liability
Enhanced efficiencies
Safer work environment
Improved quality
Audit requirements
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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
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MAINTENANCE MANAGEMENT
• What you want
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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
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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
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IN-PLANT COOPERATION
• All operating groups must participate in
equipment upkeep & maintenance
– Many companies pass on routine maintenance
and startup to production personnel
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Report problems immediately
Report on performance
Encourage input on maintenance & upkeep
Adherence to cleaning & sanitizing
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SANITATION & MAINTENANCE
• Maintenance staff must adhere to basic
principles of sanitation
• Hair restraints, cleanliness, proper clothing
• Tools & supplies under control
• Conscious of processing
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IMPLEMENTATION
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Do not try to do all at once
Work with one line or area
Be flexible
Modify program as needed
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RESPONSIBLE
PERSON
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Responsible Person
• Someone must be assigned to manage the preventive
maintenance program
– Engineering Manager
– Shop supervisor
• Person should;
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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.
COPYRIGHT RICHARD F. STIER 2011
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
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TRAINING/EDUCATION
• Production and maintenance personnel must
be trained
– Work instructions
– Procedures
• Quality, safety and sanitation
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DOCUMENTED
PROCEDURES
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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
COPYRIGHT RICHARD F. STIER 2011
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
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RECORDS
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RECORDKEEPING
“If it’s not written down it never
happened.”
United States Food & Drug Administration
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RECORDKEEPING
“In God we trust. But everyone else
has to give us data and records.”
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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
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SYSTEM
AUDITS
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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
COPYRIGHT RICHARD F. STIER 2011
System Verification
• Internal auditors must be trained to do audits
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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”
COPYRIGHT RICHARD F. STIER 2011
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
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Data recorded when record or observation taken
Corrections made properly
Proper pens and forms employed
Other
COPYRIGHT RICHARD F. STIER 2011
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
COPYRIGHT RICHARD F. STIER 2011
PREVENTIVE MAINTENANCE
• Three Part Implementation
– Inventory & Understand Equipment
– Develop Procedures for Inspection & Maintenance
– Develop Recordkeeping Procedures
• Involve All Operating Groups
• Implement Program Gradually
COPYRIGHT RICHARD F. STIER 2011
PREVENTIVE MAINTENANCE
• Help to Assure Food Safety
• Help to Assure Food
Quality
• Minimize Product
Adulteration
• Enhance Efficiencies
• Save MONEY
COPYRIGHT RICHARD F. STIER 2011