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IConnectVA

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Posted 24 May 2012 - 05:23 PM

Hi all!

I'm new here, just accepted a few days ago. So far, incredibly valuable resource!
I'm preparing for our first inspection and am developing ness docs for operations.
I've begun by outlining the required specification directly as AIB has. From here, I've broken the 'manual' down into several sub parts to include, 'description/training,' 'HACCP,' 'Cleaning Procedures,' 'Program Procedures,' 'Accountability,' and 'Mock Audit.'
From there, I'm a bit bogged down. I'm generally able to develop procedures, but am not sure what exactly I need for all of these. Same goes for Cleaning Procedures.

Can someone help with example AIB program procedures and example AIB cleaning procedures.
We blend sugars and other dry ingredients (granules and powder) and package for Distributors (1 case= 12 individually sealed 1.5lb bags)

Thanks so much!
Robert



IConnectVA

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Posted 25 May 2012 - 08:37 PM

I've got a series of documents compiled that I feel adequately address these standards. Possibly an edit with suggested revisions?
This certification is very much similar to SQF Guidelines, just not as extensive. An SQF set would likely help significantly. Let me know how to get your help!

Thanks Team!



mgourley

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Posted 26 May 2012 - 01:12 PM

Hi all!

I'm new here, just accepted a few days ago. So far, incredibly valuable resource!
I'm preparing for our first inspection and am developing ness docs for operations.
I've begun by outlining the required specification directly as AIB has. From here, I've broken the 'manual' down into several sub parts to include, 'description/training,' 'HACCP,' 'Cleaning Procedures,' 'Program Procedures,' 'Accountability,' and 'Mock Audit.'
From there, I'm a bit bogged down. I'm generally able to develop procedures, but am not sure what exactly I need for all of these. Same goes for Cleaning Procedures.

Can someone help with example AIB program procedures and example AIB cleaning procedures.
We blend sugars and other dry ingredients (granules and powder) and package for Distributors (1 case= 12 individually sealed 1.5lb bags)

Thanks so much!
Robert


I'm not quite sure what you are looking for here. If you are asking about a "format" for programs or cleaning procedures, AIB does not require one. As long as all the critical and minor requirements are addressed, any format will do.

For example, cleaning procedures:
5.13.1.4 The facility has written cleaning procedures for all equipment, structures, and grounds that impact the storage, processing and packaging of food products.

5.13.1.5 Equipment cleaning procedures address:
Chemicals
Chemical concentrations
Tools
Disassembly instructions

So, as long as you have that covered, you satisfy the requirement. I keep my Master Cleaning Schedule and Cleaning Procedures in Access. I have attached an example procedure.

As far as programs go, I would recommend starting in the Adequacy of Prerequisite and Food Safety Programs section.
You should have a written program for each one of the clauses in this section. The requirements tell you what your program must address.
After you have all these programs, place them IN ORDER in a three ring binder. This makes it very easy for you and the auditor when it's time to review paperwork. Simply hand over the binder to the auditor and he can go through it in the same order as his audit software is set up.

After you are done with the programs for the AP section, start at the beginning of the standard and carefully read. Where it says "program" or "procedure", obviously you will need a program or procedure.

For example, in section 1.33 Health Conditions:
1.33.1.4 The facility follows procedures requiring personnel, including temporary workers to notify supervisory personnel of any relevant infectious disease or conditions to which they may have been exposed.

So, you will need to address this someplace in one of your programs. I stick it in with the Personal Hygiene Program.

Or, 2.15 Temporary Repair Materials
Temporary repairs are sometimes needed or unavoidable. Procedures to ensure that they do not become a contamination hazard are defined.

So, you need a temporary repair policy that states what you do to meet the intent of the requirements in section 2.15.

Section 1.12 deals with Raw Material Transfer. I have attached my procedure for that.

Hope this helps,

Marshall

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IConnectVA

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Posted 13 June 2012 - 07:51 PM

Marshall,

My hopeful goal is to create an overly encompassing document that would likely adequately address SQF standards with simple revision.
As our facility isn't large enough at this point to warrant SQF certification, I'd like to adhere to such. I feel we've reached that critical point, not only would i like to fulfill what's required at our level of growth, but I'd like to be generally prepared for the next level of growth.

Make sense?
I've literally never seen one of these manuals. I'm simply writing blindly to adhere to a simple set of standards, but would really like to access the real deal in a related industry that I could further focus and mold my operations as suitable for larger regulatory bodies.

Thanks for your help!



mgourley

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Posted 13 June 2012 - 08:46 PM

Marshall,

My hopeful goal is to create an overly encompassing document that would likely adequately address SQF standards with simple revision.
As our facility isn't large enough at this point to warrant SQF certification, I'd like to adhere to such. I feel we've reached that critical point, not only would i like to fulfill what's required at our level of growth, but I'd like to be generally prepared for the next level of growth.

Make sense?
I've literally never seen one of these manuals. I'm simply writing blindly to adhere to a simple set of standards, but would really like to access the real deal in a related industry that I could further focus and mold my operations as suitable for larger regulatory bodies.

Thanks for your help!


I'm in a completely different industry, but if your goal is to certify to SQF, then I would get the SQF Standard and prepare a manual based upon the SQF requirements.
There are plenty of examples on this forum and elsewhere. My advice, however, would not be to have one "overly encompassing document". That just becomes a giant PITA to maintain.

BRC and SQF require that you have a "Food Safety and Quality Manual" or equivalent, that spells out what your company does to meet the intent of the Standard. This can often be as simple as restating the standard and then reference the programs, work instructions, etc., that provide more specificity.
This approach means that you generally do not have to update the base manual, just the individual policies or procedures as those change. (Which they will).

AIB does not require a "manual" per se... they just require that you have the policies, programs, paperwork, etc. that verify that you are doing what you are supposed to do to meet the intent of the requirements of the AIB Standard. Also, there are a couple of AIB requirements that are not contained in BRC (and maybe SQF). The "Material Transfer" example I posted is one.

I keep a separate binder for AIB and BRC. Both contain the appropriate (and for the most part, identical content), but are set up differently to make it easier on audit day.

Marshall

I don't know what your IT infrastructure is like, but here is what I do. Quick overview only.
1) Food Safety and Quality Manual is maintained in HTML format with links to all required "static" documentation in PDF. This document is available to all relevant staff.
2) This is maintained on a server that is backed up daily.
3) When a policy or procedure is changed, it is approved by me, I update the document change information and then it is authorized by the appropriate person and digitally signed.
4) This means that the most current information is always available to staff that require it.
5) Auditors can just read the manual and then click through to the supporting documentation.

Edited by mgourley, 13 June 2012 - 09:03 PM.


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IConnectVA

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Posted 15 June 2012 - 05:50 PM

Thanks for the help Marshall.

Our 'IT Infrastructure' is nil. :)

We've been able to function for nearly 10 years without much regulation, and our current clients don't require such. But, as we've recently introduced a new product we've gotten considerable attention from some major potential clients. These clients require extensive certifications and inspections that we just have yet to face.

In good practice, I'm aiming to complete a good number of these processes before negotiations become 'serious.' As such, our team has had their SQF, HACCP and other relevant training and we're now preparing for the inspections process.
Our auditor suggested we first seek inspection from AIB and follow up with SQF once we've successfully fulfilled requirements of the AIB inspection. After extensive review of AIB practice, I feel we're adequately prepared for AIB inspection. Thanks to that, I'd like to prepare all written procedures to include training procedures, SOP's, and all other relevant documentation. My hope is that this will allow us to not only fly through AIB certification, but allow us a brief 'review' of our material before our Mock Audit and Final SQF walk throughs.

This is a process that takes a considerable amount of time to get through, and as such, I'd like to have all of my ducks in a row so that the process goes without problems and keeps our timeline as short as possible.



IConnectVA

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Posted 15 June 2012 - 05:52 PM

AIB Inspection, mind you, not certification :) It all gets jumbled in here!



mgourley

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Posted 15 June 2012 - 10:20 PM

Thanks for the help Marshall.

Our 'IT Infrastructure' is nil. :)

We've been able to function for nearly 10 years without much regulation, and our current clients don't require such. But, as we've recently introduced a new product we've gotten considerable attention from some major potential clients. These clients require extensive certifications and inspections that we just have yet to face.

In good practice, I'm aiming to complete a good number of these processes before negotiations become 'serious.' As such, our team has had their SQF, HACCP and other relevant training and we're now preparing for the inspections process.
Our auditor suggested we first seek inspection from AIB and follow up with SQF once we've successfully fulfilled requirements of the AIB inspection. After extensive review of AIB practice, I feel we're adequately prepared for AIB inspection. Thanks to that, I'd like to prepare all written procedures to include training procedures, SOP's, and all other relevant documentation. My hope is that this will allow us to not only fly through AIB certification, but allow us a brief 'review' of our material before our Mock Audit and Final SQF walk throughs.

This is a process that takes a considerable amount of time to get through, and as such, I'd like to have all of my ducks in a row so that the process goes without problems and keeps our timeline as short as possible.


You certainly can contact AIB and schedule a training audit. It will be the same audit you would get if it were a "scored" audit. That would give you an idea where you stack up in relation to their standard.

Don't expect that you can schedule that audit on a specific day(s) though. AIB auditors are responsible for making their own schedules and they may or may not be able to fit you in to their existing schedule.

Since future clients seem to want some certification, it's certainly worth the money to schedule some mock audits to see where you stand.

AIB will be able to offer assistance in those areas you are lacking.
I do not believe the SQF certification body will be able to do that, if you use that same certification body for the actual certification process. (SQF people correct me here if this is incorrect).

Marshall

Edited by mgourley, 15 June 2012 - 10:21 PM.


IConnectVA

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Posted 16 June 2012 - 04:37 AM

Really?
What's the deal there?

We've had our initial mock audit roughly 50 days ago.
Seems we were in fair shape and 'written procedures' weren't as important as SQF.
Obviously this damaged our overall score, but we still had a pretty good standing.

But, if I'm understanding you correctly, if Auditor A performs audit or 'AIB Inspection' and Auditor A then performs audit or 'SQF Certification,' then said 'Auditor A' will not be able to provide 'guidance?' Seems a little goofy.

I've compiled a nearly 160 pg set of documents that I feel can fairly adequately address each AIB Standard directly. I just wonder if that puts me closer to SQF guidelines. I'm really not looking forward to having to write an additional series of operations which are going to address SQF Standards.

I've barely bumbled through this guy!

Any resources on that? Any interest in seeing my sorely compiled list of operations procedures, piecemeal from other forums? Could really use some solid guidance as I don't feel it's feasible for our operation to seek 'professional guidance' at a rate of $900.



IConnectVA

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Posted 16 June 2012 - 04:45 AM

'Glenn' in another forum says:

And, a general statement.... Auditors are NOT allowed to make recommendations/suggestions - they are at your facility to conduct an audit plain and simple, it is a direct violation of the SQF Code of Practice for Auditors to make suggestions/demands/recommendations.


That's pretty plain and simple.



mgourley

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Posted 16 June 2012 - 10:00 AM

Really?
What's the deal there?

We've had our initial mock audit roughly 50 days ago.
Seems we were in fair shape and 'written procedures' weren't as important as SQF.
Obviously this damaged our overall score, but we still had a pretty good standing.

But, if I'm understanding you correctly, if Auditor A performs audit or 'AIB Inspection' and Auditor A then performs audit or 'SQF Certification,' then said 'Auditor A' will not be able to provide 'guidance?' Seems a little goofy.

I've compiled a nearly 160 pg set of documents that I feel can fairly adequately address each AIB Standard directly. I just wonder if that puts me closer to SQF guidelines. I'm really not looking forward to having to write an additional series of operations which are going to address SQF Standards.

I've barely bumbled through this guy!

Any resources on that? Any interest in seeing my sorely compiled list of operations procedures, piecemeal from other forums? Could really use some solid guidance as I don't feel it's feasible for our operation to seek 'professional guidance' at a rate of $900.


I'd be happy to look at what you have and provide any suggestions.

Marshall


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Posted 16 June 2012 - 03:55 PM

'Glenn' in another forum says:

And, a general statement.... Auditors are NOT allowed to make recommendations/suggestions - they are at your facility to conduct an audit plain and simple, it is a direct violation of the SQF Code of Practice for Auditors to make suggestions/demands/recommendations.


That's pretty plain and simple.


Dear IConnectVA,

That's pretty plain and simple.


In the context of auditing, I'm afraid this is wishful thinking . :smile:

You are probably oversimplifying, eg seeing everything as black or white. IMEX, an auditor, intentionally or otherwise, cannot avoid offering guidance if properly "utilised" by the auditee. After all, you are the one paying.

The question as to who can audit who/what/where/when can be operationally and possibly geographically complicated. The basic requirement, I guess, revolves around independence which can be a very grey topic.

Unfortunately there are not so many users of AIB on this forum compared to BRC/SQF so Mgourley is probably a lucky find for you. :smile:
Based on limited field experience, i agree his comment that AIB is likely to be far less structure/format-sensitive than SQF/BRC/IFS however it is almost axiomatic that you need some kind of documentation to correspond to specified procedures within the standard's text. Traditionally the old ISO may/must/shall interpretation should operate but this rigidity seems non-existent these days.

I deduce you hv now completed most of the various procedures referred in yr original post. I'm sure that if you wish to post any, people with (or maybe even without) the appropriate competence will be happy to make some comments. (I seem to remember the AIB standard is accessible on-line?)

Regarding a composite manual, you might try a little searching here, eg "AIB SQF manual" (a direct search for AIB will fail due need >=4letters). Offhand I can't remember seeing yr specific query pair before, combinations of brc/sqf/iso22000 are more common.

Rgds / Charles.C

Kind Regards,

 

Charles.C


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Posted 27 March 2015 - 02:49 PM

I'm not quite sure what you are looking for here. If you are asking about a "format" for programs or cleaning procedures, AIB does not require one. As long as all the critical and minor requirements are addressed, any format will do.

For example, cleaning procedures:
5.13.1.4 The facility has written cleaning procedures for all equipment, structures, and grounds that impact the storage, processing and packaging of food products.

5.13.1.5 Equipment cleaning procedures address:
Chemicals
Chemical concentrations
Tools
Disassembly instructions

So, as long as you have that covered, you satisfy the requirement. I keep my Master Cleaning Schedule and Cleaning Procedures in Access. I have attached an example procedure.

As far as programs go, I would recommend starting in the Adequacy of Prerequisite and Food Safety Programs section.
You should have a written program for each one of the clauses in this section. The requirements tell you what your program must address.
After you have all these programs, place them IN ORDER in a three ring binder. This makes it very easy for you and the auditor when it's time to review paperwork. Simply hand over the binder to the auditor and he can go through it in the same order as his audit software is set up.

After you are done with the programs for the AP section, start at the beginning of the standard and carefully read. Where it says "program" or "procedure", obviously you will need a program or procedure.

For example, in section 1.33 Health Conditions:
1.33.1.4 The facility follows procedures requiring personnel, including temporary workers to notify supervisory personnel of any relevant infectious disease or conditions to which they may have been exposed.

So, you will need to address this someplace in one of your programs. I stick it in with the Personal Hygiene Program.

Or, 2.15 Temporary Repair Materials
Temporary repairs are sometimes needed or unavoidable. Procedures to ensure that they do not become a contamination hazard are defined.

So, you need a temporary repair policy that states what you do to meet the intent of the requirements in section 2.15.

Section 1.12 deals with Raw Material Transfer. I have attached my procedure for that.

Hope this helps,

Marshall

 

Hi Marshall,

 

I know this is a very old post but I just wanted to say thank you for those documents!  I'm new at all of this and sometimes I get so bogged down in the details that I forget a simple procedure can be very effective.  Thank you!



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Posted 27 March 2015 - 06:42 PM

Hello Robert -

 

We just went through our first inspection/certification from AIB last January. We got 975 out of 1000. First off, have you gone through AIB Consolidated Standards for Inspection? Each one of their parts or Highlighted Statements requires an SOP to respond to it and a checklist to verify it. Secondly, they will go through your place with a fine toothed comb. Anything within reach of your production line must be immaculately cleaned. Your HACCP program - all CCPs must be verifiable and validated. You must have all your prerequisite programs in order combined with appropriate SOPs for each. Their focus is in two stages. The first stage is sanitation and pest control. They will look at every piece of documents that are provided by your pest control service. Next they will walk through your plant and believe me they see things you wouldn't think of looking at. So make sure EVERYTHING is clean. No chipped paint, rust or tape. The second stage is the documentation. Use their notation not yours to identify documents. For example. Pest control is 4.1 so your document should state the same at the top or they'll think you're disorganized and tell you so. Have the documents in their own files so when asked you can just hand the file to them. Preparation is everything! They are no nonsense so don't try and be their friend. Don't be social, stay focused. Have everything within reach to hand to them. If you need to, contact me at dpk1955@yahoo.com. Good luck! Dan



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