Meat Plants Auditing

Meat Plants Auditing

MEAT PLANTS AUDITING

Many views may be expressed on the most appropriate and suitable method of auditing other plants to assess their fitness (or otherwise) to be listed as an approved supplier. Some of them may already have been discussed, such as being accredited to one of the quality standards for various factors such as BRC Global standard, ISO 9000, ISO14000, OHSAS 18000 or ISO 22000 and perhaps others that have not been mentioned. However, on occasion it may be necessary to conduct an ‘on site’ audit to provide evidence that your company, as a business, is taking a very serious view of ensuring that standards provided by suppliers are indeed being maintained in the manner that you want. Equally, as the operator of a meat plant it may be a case of needing to carry out an assessment of just how your own standards are bearing up when put under scrutiny. In either case, one point that must be ensured is that any audit should provide a ‘balanced and consistent’ approach from one audit to another and from one auditor to another auditor.

The following procedure is one that has been adapted and extended from the U.S. military standard for assessment of hygiene compliance in meat plants outside the U.S.A. Although some parts have been changed to ’fit the purpose’ sincere acknowledgements are given here to the U.S. military inspectorate for the basic layout and concept. Generally their standard is referred to as MIL-STD, followed by a number referencing the version that is applicable. The original standard and much of it, as used here, is principally aimed at hygiene standards in abattoirs and meat cutting plants but using the same basic concept, the consistency can be maintained in highlighting other quality aspects into an audit and allocating relevant demerit points for the items. Similarly, the inclusion of items which are more apparent in cooked meats or cured meats plants can be included. In adapting this form though, the basic concept as it was subsequently adapted for use from that basic MIL-STD some items have already been added and, in various trials using it in its earlier days, the procedure shown here did prove to be extremely effective and also to be very consistent. On one of the very early tests of its efficiency the same forms were used at the same plant, on the same day by one of the board directors of the company, a meat cutter taken from the production line, the Official site Veterinarian and also one of the technical team at the plant. The procedure was explained to all of them and they each separately set about carrying out an audit, each starting at a different part of the plant but in total covering the entire plant. Each audit provided figures that were quickly calculated to give a percentage rating from each auditor. Of the 4 audits carried out on that occasion the difference in the final figures obtained from each of the 4 audits was less than 1 percent. The intention is to assess all of the plant to constant criteria and to allocate ‘demerit points’ only up to a given maximum for any item that is judged to be at fault. On some parts there may be no demerit points allocated, on others, where there is a fault the noted item may have a maximum available to give of say 4 demerit points. The auditor then selects a score to reflect the degree of the demerit. The points allocated may be 1 or 2 or 3 or even the full 4 or 5 points. In extremely rare occurrences where a particular item seen appears to be a potential real risk to the well being of customers and an absolute danger then the demerit points may be over ridden by the allocation of a ‘critical’ scoring. Where a ‘critical’ score has been given, the entire audit must cease as the plant has ‘failed’ and must urgently deal with any critical points that have been shown.

Where no critical defects have been identified, the percentage rating of the audit for the plant uses the following calculation:

The sum of Column “C” demerit points minus the sum of Column “D” demerit points,

______x 100

Divided by the sum of Column ”C” demerit points

This is a system that has been found to be capable of giving a consistency in the results and may prove to be useful. It is by no means the only system but is shown here as an example only but if indeed other systems provide some degree of support and are capable of being repeated in a consistent manner then they could just as easily be used.

Do try and find a system that enables, from evidence gained on an audit (or plant inspection) a definite result that can be examined and quantified. In this way, any supplier who has been audited (or inspected) can examine the findings and react to them to correct any deficiencies noted.

In using a percentage system it is possible to have a more definite ‘pass’ or ‘fail’ figure for everyone to recognise, rather than one persons opinion, be it right or wrong. A reasonable figure to take as a ‘pass’ percentage can be of the order of 90% compliance, or if this is regarded as being too relaxed it may be set at 95% compliance. Whatever the figure, that figure must be maintained as a constant and used every time.

It will be noticed that some ‘blank’ rows have been left on some sections in order that any additional items that may be more pertinent to a particular business may be added, if required. Whatever happens to the changes though must remain as a constant addition since it would be most unreasonable to operate with ‘one system on one audit and another system on the next audit’.

It is possible, using such a system as the one shown here, to leave a copy with the plant that has been inspected in order that they may carry out their own internal audits to ensure that they WILL comply whenever inspected.

The inspection forms shown here now have has been separated to enable approximately A4 sheets to be saved, amended as required (after appropriate separation) or be printed if they should be required.

The audits for the BRC Global Standard or the ISO 9000 or 22000 DO NOT use this kind of form so in order to carry out an audit to those standards some specific training would be required for each individual auditor. If the results are better or worse, one against the other, is a matter of choice but there is no reason why both cannot be used since the use of the one shown here does demonstrate a compliance to a good standard, although in this form it concentrates much more on hygiene. If compliance is being achieved here though it is quite probable that the company will be following most other aspects of the system that they are using.

The following pages are suggestions of a simple but effective set of auditing forms to be used either as a ‘self audit’ of the ‘home plant’ or when carrying out an audit of a supplier. They may of course be adapted to take account of other points that are more relevant with an appropriate demerit score being put in place. Do try to keep them consistent with the plant (s) being audited and if they are to be used on several plants then the contents need to be consistent throughout to give an accurate reflection of the standards being achieved.

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“A”
ITEM NUMBER / “B”
POTENTIAL DEFECTS TO NOTE / “C”
Assigned Demerit
Points / “D”
Auditors Demerit Points
1 / EXTERNAL APPEARANCE AND OUTSIDE AREAS
1a / Lack of security capabilities for the site / 3
1b / Poor drainage possibly leading to nuisance / 3
1c / Unfinished roadways and surfaces permitting “pooling” of water etc. / 3
1d / Not clean and well organised / 3
1e / Overgrowth of weeds etc leading to potential breeding ground for pests / 3
1f / Collections of debris or unused items possibly leading to harbourage for vermin and / or other pests / 3
2 / RAW MATERIALS
2a / Not obtained from approved sources / Critical
2b / Inadequate inspection of goods on arrival to determine any levels of adulteration, contamination or infestation / 5
2c / Inadequate facilities for carrying out ante mortem inspections or ante mortem inspections not being carried out / Critical
2d / Inadequate separation of packaging materials and food materials / 4
3 / CONSTRUCTION OF BUILDINGS
3a / Buildings, floor falls and /or drainage inadequate for the operation being carried out / 4
3b / Inadequate separation of functions within rooms or buildings / 4
3c / Walls, floors and ceilings not constructed of suitable waterproof and impervious materials / 4
3d / Inadequate facilities in slaughter area for individual processes being carried out and with all areas to have hand wash facilities and equipment sterilizers within easy reach of each worker / 4
3e / Lack of isolation pens / facilities for sick or injured animals to await slaughter / 4
3f / Inadequate lairages, inadequate unloading areas for lairages. Lairages not satisfying needs of animal welfare. Lairage pens with inadequate water troughs, feeding racks etc. / 4
3g / Inadequate facilities and standards maintained for stunning in confined stunning pens: Slaughter of animals not being done to approved standards of both hygiene and welfare / Critical
ItemItem
“A” / Item
“B”
POTENTIAL DEFECTS TO N0TE / Item
“C” / Item
“D”
3 / CONSTRUCTION
(Continued) / Assigned Demerit
Points / Auditors Demerit
Points
3h / Unnecessary overhead clutter of wires, pipes, hangers etc. causing potential hygiene problems / 4
3i / Inadequate screening to outdoor areas, maintenance areas or doors to outside areas or maintenance areas are left open. / 4
3j / Inadequate facilities for dealing with hides and green offal / 4
3k / Inadequate facilities for bleeding system for animals to be bled while suspended with a proper col-lection area for blood and / or for the dressing of the animals to be carried out in a hygienic manner / Critical
3l / Inadequate inspection points provided for each function as needed and with appropriate facilities for hand wash and equipment wash and sterilization / 4
3m / Inadequate facilities under chill conditions for holding carcasses and organs pending further examinations / Critical
3n / Inadequate recording of temperatures of equipment sterilizers and equipment sterilizers not operating at the correct temperature of 82°C or more for sterilization or being drained into an appropriate sealed floor drain / Critical
4 / LIGHTING
4a / Insufficient lighting for inspection purposes / 4
4b / Insufficient lighting in work areas / 3
4c / Lighting in food areas not adequately protected to contain breakages in the event of accidents or blow outs. / 5
5 / REFRIGERATION, VENTILATION AND HUMIDITY / 5
5a / External opening windows not provided with close fitting mesh to prevent access of insects etc. / 3
5b / Windows present with 'ledges' capable of harbouring soils and contaminants / 5
5c / Noted air movement from heavier contamination to areas of 'higher risk‟ products or possible cause of contamination of products. Insufficient control over air movement. / 5
5d / Presence of mould growth on walls and / or ceilings indicating poor controls / 5
5e / Ventilation system not kept clean and in good repair / 5
5f / Presence of noticeable condensate on walls etc in processing and / or storage areas / 5
5g / Chillers and Freezers not maintained in a clean and orderly manner / 5
5h / Product being stored at incorrect temperatures (frozen goods in chillers / chilled product in freezers etc.) / 5
“A”
ITEM NUMBER / “B”
POTENTIAL DEFECTS TO NOTE / “C”
Assigned Demerit
Points / “D”
Auditors Demerit Points
5 / REFRIGERATION, VENTILATION AND HUMIDITY
(continued)
5i / No records being maintained of chillers, freezers and work rooms operating temperatures / Critical
5j / Boning / cutting / processing rooms operating at temperatures greater than 10°C / 5
5k / Inadequate cleaning of chiller and freezer condensing unit fans etc. / 5
5l / Evidence of ice build up in freezers on walls / floors etc. / 5
6 / WATER SUPPLY (INCLUDING THE USE OF ICE)
6a / Inadequate quantity of total water supply / 5
6b / Inadequate supply of hot water (for hand wash and /or for equipment cleaning) / 5
6c / Cross connection between potable and non potable water supplies / Critical
6d / No records available of water test results to prove potability status or certificates out of date / Critical
6e / Inadequate protection to prevent back siphoning of water into mains / Critical
6f / Potable water found to be unpotable / Critical
6g / Non potable water outlets not marked as being a non potable source of water / 5
6h / Inadequate numbers of wash hand basins / equipment sterilizers for the areas of food work or for the type of work involved. / 5
6I / Ice not being made from potable water / Critical
6j / Ice not manufactured, stored or used in a hygienic manner / 5
“A”
ITEM NUMBER / “B”
POTENTIAL DEFECTS TO NOTE / “C”
Assigned Demerit
Points / “D”
Auditors Demerit Points
7 / DISPOSAL OF WASTES AND WASTE MATERIALS
7a / Liquid waste not disposed of in a suitable manner / 4
7b / Floor drainage inadequate; Inadequate fall, drains inappropriate for function; drains of incorrect size; drains not properly trapped and / or cleaned / 4
7c / Waste materials not collected in appropriate containers with close fitting lids and / or not disposed of at regular and frequent intervals / 3
7d / Inedible product containers (and rooms) not properly identified and secured / 4
7e / Inadequate facilities available for moving unfit and condemned materials / 5
7f / Inadequate separation of inedible and / or unfit products from edible products being processed / 5
7g / Condemned, inedible and / or restricted products not being maintained under strict inspectorial control / Critical
8 / TOILETS CHANGING ROOMS AND HAND AND EQUIPMENT WASH FACILITIES
8a / Insufficient numbers of toilets and / or urinals provided / 4
8b / Toilet rooms not conveniently located and / or so constructed of materials that are not easily cleaned. / 4
8c / Inadequate lighting in toilets / 2
8d / Toilets not ventilated to an external area / 4
8e / Absence of properly ventilated area between toilets and workrooms / 5
8f / Absence of proper hand wash signs / 4
8g / Absence of water at a suitably controlled temperature and / or appropriate soap materials, disposable hand towels and receptacles to hold used towels. / 4
8h / Absence of sanitary waste disposal containers / 3
“A”
ITEM NUMBER / “B”
POTENTIAL DEFECTS TO NOTE / “C”
Assigned Demerit
Points / “D”
Auditors Demerit Points
8 / TOILETS CHANGING ROOMS AND HAND AND EQUIPMENT WASH FACILITIES (Continued)
8i / Changing area being used as a storage area for cleaning equipment and / or stocks of detergents / 5
8j / Toilets not being adequately separated from work areas / Critical
8k / Inadequate changing room lockers of such type and number for workers to enable a full separation of outdoor clothing from food processing clothing / 5
8l / Absence of ventilated air space between toilets and changing rooms / 3
8m / Shower or bath facilities not provided when required. / 5
8n / Toilets, associated hand wash areas and changing rooms not being maintained in a clean, orderly and workable manner. / 4
9 / CONSTRUCTION AND REPAIR OF EQUIPMENT AND UTENSILS
9a / Production, design and / or use of the equipment and / or utensils does not preclude the contamination of food / Critical
9b / Product contact surfaces not constructed of impervious material with a smooth and non corrosion type surface / 5
9c / Product contact surfaces not constructed of a non toxic material / Critical
9d / Equipment, materials and surfaces not being maintained in a good state of repair and being kept clean / 5
9e / Constructed in such a manner that prevents all product surfaces from being easily sanitised / 5
9f / Equipment not easily accessible for cleaning, maintenance and inspection / 5
“A”
ITEM NUMBER / “B”
POTENTIAL DEFECTS TO NOTE / “C”
Assigned
Demerit
Points / “D”
Auditors Demerit Points
10 / CLEANING AND SANITIZATION TREATMENT
10a / Inadequate cleaning and or sanitising methods which fail to prevent product contamination or adulteration / Critical
10b / Plant cleaning commenced prior to removal of all product giving risk of product contamination or adulteration / Critical
10c / Inadequate procedure to ensure proper cleaning and sterilization of equipment and containers prior to re use with any food products / Critical
10d / Cleaning and sterilizing chemicals not properly labelled and/or stored under controlled conditions / 5
10e / Unauthorised and/or improper chemicals permitted to be used for cleaning within the plant or area surrounding it / Critical
10f / Test kits not available or not being used when chemical sterilizing of equipment is practised / 5
10g / Equipment sterilizers are using hot water that is not being maintained at 82°C or greater - records of temperature checks not being maintained. / 5
10h / Rooms and food areas not being maintained and/or operated in a clean and hygienic manner - cleaning check sheets not being used, acknowledged or checked. / 5
10j / Inadequate location of equipment sterilizers in relation to work stations / Critical
11 / METHODS, SYSTEMS AND CONTROLS.
11a / Methods of production used are such that they permit contamination or adulteration of product / Critical
11b / Inadequate control of product stockholding that may permit deterioration of the product / 5
11c / Inadequate procedural control to prevent contamination of product from visceral contents during slaughter process / Critical
11d / Adequate and appropriate marked and lockable containers not available to hold meat and or viscera retained for further inspection / Critical
11e / Methods used for detection of metal or other foreign body materials in product are inadequate / Critical
11f / Inadequate testing of devices used for metal detection and lack of records of tests carried out / Critical
11g / Surfaces and equipment used for handling meat AND other products not colour coded to minimise risks of adulteration / 5
11h / HACCP records (including minutes of HACCP meetings) unavailable indicating HACCP not practised / Critical
“A”
ITEM NUMBER / “B”
POTENTIAL DEFECTS TO NOTE / “C”
Assigned
Demerit
Points / “D”
Auditors Demerit Points
11 / METHODS, SYSTEMS AND CONTROLS.
(continued)
11i / Lack of security in admission of visitors without completing health & hygiene declaration / 5
11j / Lack of evidence of workers training in skills / 3
11k / Inadequate and / or ineffective pest control in operation / 5
12 / CHILLERS REFRIGERATORS AND FREEZERS
12a / Chillers and / or freezers not free from objectionable odours / 5
12b / Chillers and / or freezers not maintained in a clean and hygienic manner / 5
12c / Product not being stored at correct temperatures / 5
12d / Workrooms and areas adjacent to chillers being operated at unacceptable temperatures (above 10°C) / 5
13 / STORING AND STORAGE FACILITIES
13a / Storage facilities not in good repair or maintained in a clean condition / 4
13b / Inadequate stock control operating in storage areas to minimise risk of product deterioration / 5
13c / Inadequate precautions taken to prevent damage to stored materials in stockholding areas / 5
13d / Product stored in such a manner as to hinder proper cleaning or pest control beneath product / 5
13e / Inadequate separation between stockholding of packaging materials and open foodstuffs / 4
14 / CONTROL OF INSECTS, BIRDS, VERMIN AND OTHER PESTS
14a / Presence of insects, birds, vermin or other pests in production area / Critical
14b / Presence of insects, birds, vermin or other pests in non- production area / 5
14c / Effective pest control programme not in place at all times / 4
14d / Improper storage of materials close to buildings providing harbourage for rodents and other pests / 5
“A”
ITEM NUMBER / “B”
POTENTIAL DEFECTS TO NOTE / “C”
Assigned Demerit
Points / “D”
Auditors Demerit Points
14 / CONTROL OF INSECTS, BIRDS, VERMIN AND OTHER PESTS
14e / Unauthorised pesticides or rodenticide being used / Critical
14f / Insecticides or rodenticide materials not being used in the manner of the of labelled directions / 5
14g / Insecticides or rodenticide materials not being stored in a proper and safe manner / 5
14h / Electrical insectocutors being sited above food areas or in such a manner that electrocuted insects may fall into food / 5
15 / VEHICLE AND TRANSPORT FACILITIES
15a / Vehicles or containers not constructed or operated to protect contents from contamination or deterioration / Critical
15b / Vehicles or containers not being properly maintained or not in a clean condition / 5
15c / Vehicles not fitted with refrigeration units capable of maintaining temperatures needed for product to be carried / 5
15d / Vehicles not fitted with Thermographic recording devices / 3
16 / CLEANLINESS OF PERSONNEL
16a / Failure of food workers to be hygienically clean / 5
16b / Failure of food workers to wash hands after any contamination / Critical
16c / Personnel not prohibited from eating, smoking or spitting in any product handling areas / 5
16d / Personnel permitted to ear jewellery (other than a plain wedding ring), nail varnish and/or strong perfumes in food production areas / 5
16e / Personnel permitted to enter food areas without wearing appropriate hair and head covering / 5
16f / Personnel permitted to enter food areas without wearing appropriate protective clothing which must include overclothing and protective washable footwear / 5
16g / Storage of employee's personal property in any part of a production room / 3
16h / Workers affected with, or being a carrier of, any infectious disease or condition being permitted to work in any product area / Critical
16i / Workers having an infectious wound, sore or lesion on hands, arms or other exposed parts of their body not being excluded from contacting any ingredients, products or product zones / Critical
16j / Absence of workers health certification prior to working with food / 5
16k / Lack of evidence of workers training in food hygiene / 5

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