Hi Smith,
We do not have any audit documents written here. I am in the process of developing them. I have done some but not very happy about it. I have pasted one of the GMP Audit I have done. It is too much in detail and time consuming. I am thinking I would have to consider only the important things that would cause an immediate food safety or quality risk.
GMP AUDIT SUMMARY - Packing
Serial.no Area C/NC Comments Actions
1 Cleaning of tote bins in ground floor packing. Visual checks NC Cleaned but no records After cleaning, cleaning records are filled up
and the cleaning records to be checked
2 Ground floor packing: no kibble on the floor, spillages NC kibble on floor, no kibble near line 3 as they did not run it Need to clear it up
should be immediately cleaned up
3 Test for metal detection: spot checks and check the records, line 1 C Metal detection has be done and recorded No further actions needed
6 Test for metal detection: spot checks and check the records, line 2 NC Has been done but not recorded immediately, short of people Need to write up atleast at the end for record keeping
7 Test for metal detection: spot checks and check the records, line 3 C Metal detection has be done and recorded No further actions needed
8 Tidiness of CTEC line 1 machine NC Not clean, dusty Could not clean because they were running machines on Friday, were supposed to clean up
9 Tidiness of CTEC line 2 machine NC Not clean, dusty Could not clean because they were running machines on Friday, were supposed to clean up
10 Tidiness of Toyo, line 3 machine NC Not clean, dusty with ink on the machines in few places Could not clean because they were running machines on Friday, were supposed to clean up
11 Not to have any broken pallets in packing C No broken pallets seen No further actions needed
12 Finished product bags not be placed on the floor directly NC Finished product bags on the floor SE to order hard plastic containers to put them during machine problems
13 The bags should not be striked with legs C Did not see any operator doing that No further actions needed
14 Bags should be handled properly, to avoid crushed and crumbled kibble C Did not see any operator doing that No further actions needed
complaints
15 Packaging in the warehouse is covered properly, to prevent the pests NC Few of them are not covered, others are not properly covered All the shifts should shrink wrap the packaging pallets and label them.
entry into the bags (like larvae)
16 Used packaging pallets to be wrapped and properly labelled NC Few of them are not covered, others are not properly covered All the shifts should shrink wrap the packaging pallets and label them.
17 All the equipments and items to be in its designated area, unless they NC Needs something to place the cleaning tools SE or Engg's to help the Packing have designated place to put the cleaning tools
are in use
18 Not to have any unnecessary items in packing NC metal covers & nuts on level 2, used cloth on floor level 2 Remove the nuts & bolts with metal covers in level 2, tool boxes for other tools needed
19 Quality checks to be done as mentioned and properly, to ensure we C Done well and as per the document No further actions needed
do not send bad quality product into market
20 Files in the quality station should be well maintained, in proper place NC Files are not well kept, no space? Shane needs to check and confirm as it is a space issue or just not well kept
21 Gloves to be in its designated area, used gloves to be disposed off C Kept in it's designated area No further actions needed
immediately
22 Multipurpose cloth to be in its designated area, not near any of the line NC used cloth on level 2 floor Education needed to dispose it off? Shane needs to brief the team about cleaning?
s and disposed off immediately after useage.
23 Nuts, Bolts and other maintenance tools to be in its designated area, NC nuts and bolts with metal covers on level 2 packing Engineers to take it back or place it where it should be
not to be left loose unattended
24 Drinks only in the designated area, spills of tea/coffee will be counted C no spills of water/tea/coffee No further actions needed
and given a NC.
25 The bags in the product review have to be placed well, not thrown away. C well placed bags No further actions needed
Do not want to have damaged bags in it.
26 Product review cage should only have the bags otherwise empty. C It is been used for the purpose No further actions needed
Not to use it for placing anything.
27 Waste skips for the cardboard/bags to be emptied when full and closed C emptied when full No further actions needed
at all times
28 Repack and rework big bags to be labelled and tied up with all the details C lables are filled and used the right colour coded bag No further actions needed
filled in properly, it should be legible
29 Metal detector test bars to be place in the pouches on each line C bars in the right place No further actions needed
when it is not in use.
30 Metal detector test bar pouches to be tidy without any fines or kibbles NC fines in the pouches, the pouches are not long lasting Need somehting easy to clean when dirty, SS brush like holders?
in it.
31 Kibbles from the tray's under line 1 and 2 should be cleared off when full C cleared off when full and from previous runs No further actions needed
and before the end of each shift.
32 Line 2 bag rejection bin to be emptied when full, the bags cannot over- C not full when audited No further actions needed
flow and fall on the floor.
33 No labels on the floor at the end of line 2 and also no labels on the NC Lables are stuck on the floor, end of line 2 Scrape them off during Friday clean
end of line 2 machines.
34 The weighing scale near line 3 and its table should be clean NC dusty with fines cleaning needed during Friday
35 Weighing sclaes to be cleaned for fines, do spot check. NC line 3 not cleaned from previous shift clean it when running or when have time
36 2 Black fine bins on level 1 packing to be labelled and emptied when full NC Not labelled label them up
37 2 Black fine bins on leve 1 packing to be on the cleaning schedule and no cleaning records Cleaning record to be made
check if it is cleaned or not by checking the records and visaual checks.
38 Fine collector on level 1 packing, above the weighing scales should be
clean and cleaned thoroughly once in a week. Risk of contamiantion,
if not cleaned.
39 Cleaning of the sieves in packing should go into cleaning schedule. NC No records shown Need to have cleaning record and filled up appropriately
Check the records, risk of contamination if not cleaned.
40 All the weighing sclaes, conveyor belts in packing should be clean. NC dusty with fines and greasy Thorough cleaning needed every Friday
41 Ladders in the packing should be clean NC dustry with fines Thorough cleaning needed every Friday
42 Black mat on level 1 packing to be clean and placed in a designated area C Need regular cleaning should go on to the cleaning schedule
43 PPE when used should be placed back in its designated area
44 The regrind pipes and its big bag holding metal support should be clean. NC dusty with fines should go on to the cleaning schedule & cleaned every Friday
45 Stairs in packing should be clean NC they are very dirty Cleaning up needed, very thoroughly
46 Kibbles on the floor in level 2 packing, to be no kibbles on the floor NC kibbles on floor and fines needs cleaning up and a lot of other issues are the reason for the kibble and fines to be on floor
47 No fines on the floor in packing level 1 and 2 NC
48 The fine bins in level 2 packing should be emptied when full C
It could go on the cleaning records.
49 Vacuum cleaner to be in its designated area C
50 All the cleaning tools to be in their designated areas when not in use NC
51 The packaging material must at all times, be clearly labelled NC
52 The packaging should be shrink wrapped to prevent contamination. NC
53 Outher packaging should be removed in the warehouse, followed by TBD
sanitising the hands.
54 FB Policy Audit C
55 Ear protection should be tied up to the bump caps C
56 The beams in the packing, in all levels should be dust free and clean. NC dusty
For 46, In packing level 2, for fine bins the clips are really hard to fit them back and that could possibly be the reason for fines on the floor. Need something easy and reliable.
From the silos onto the conveyor belt we do not have covers, where we have covers they are left with gaps. Need to put the covers and seal the gaps? Risk of mixed kibble? Reason for kibbles on the floor
From the conveyor belt to vibrator on line 1 has a gap that needs sealing to acoid fines and kibble on the floor.
Cable tray under line 3 needs covering, risk kibble stuck in the cable and hard to clean, becomes dusty and dirty on long run.
Weekly Audit
Should we score them to get a graph? So, we can see the trending
List of my responsibilities:
1. Product Review: I review the products made each day on the following morning and if there are any issues, will discuss in the morning meet.
2. GMP/GHP on site
3. We need to do the HACCP documentation and so I co-ordinate the process and make sure every one is completing their tasks with regard to HACCP/GMP and GHP.
4. I have written policies like Foreign Body policy which prohibits the items like jewellery, watches, non-factory mobile phones, magazines, staples, non-factory pens, food, drinks, medicine etc. Clean as you go policy, safety knife policy, smoking policy, calibration policy, glass and plastic policy etc.
5. I need to do a lot of work, I have just bought the ISO 9001:2008 standards today. With the help of it I will do more work.
6. I am responsible for the pest control on site.
7. Training with regards to food safety and quality.
8. Investigation of consumer complaints and doing KPI and organizing meetings to communicate the complaints with the Managers and related associates to reduce them.
9. Responsible for quality from the point of packing.
10. That is all as I can think now.
Thanks again
Julie