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Communication of release of product to shipping

positive release shipping release

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#1 ChocolatesMyGame

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Posted 11 August 2014 - 07:44 PM

Hi all-

I see there are many threads on here already about positive release and product release in terms of the requirements, but I'd love to hear HOW it is handled.  For a short background, I am with a company implementing SQF and we just installed our first metal detector (hooray!) that we will be considering a release criteria.  This includes that I (Quality Assurance) must review the metal detection paperwork prior to release of the product for shipping.  Wow, did I get the push back from warehouse and production because everyone feels this will take up "too much time" as they sometimes would like to ship same day as made.  I've explained that Quality needs to be built into the lead times, but anyway...  We still do mostly everything on paper and don't have an electronic method such as an ERP system to communicate release so somewhere, somehow, someone needs to verify the lot being pulled for orders is released.

 

 Is there anyone out there who does it all on paper and has a good method for positive release of product?  If so, do you mind sharing how you ensure product remains in house until all paperwork has passed, and how you communicate it?

 

Much appreciated!


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#2 fgjuadi

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Posted 12 August 2014 - 04:49 PM

I'm also putting together a positive release SOP on the back burner - right now we are operating on negative release. 

 

At a previous company, we used the COA as a release step - can't ship without a COA, QA only can issue once testing is back.  Now that our customers don't require COAs, it isn't as easy.

 

I've also worked at a place where I kept lab results in my log book and every day the shipping manager would come in to make sure I'd signed off on the lots he was going to ship & sign that he has confirmed release.   Maybe it can be included as an item in your Shipping / Outgoing  Trailer Inspection?

 

We sell things to individuals - truffle boxes can have up to 30 different types of truffle, custom by order, so there would be a ton of batch sheets to review - so before truffles are "released" to wrapping, I inspect the metal detector logs & we run sensory on each batch.  Completed truffles are put on hold until I sign off & then moved to the wrapping area once they are good to go.  

 

I too would  like an efficient, simple way to make sure this is done for every shipment - sometimes shipments contain a good number of different lots, and often one lot is used in several shipments.  Orders are generally produced the same day they are shipped.  So...bump. 


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#3 Charles.C

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Posted 13 August 2014 - 04:45 AM

Dear CMG/ Magenta_m,

 

The previous posts imply that the (satisfactory) MD data is the sole criterion required by RA for concluding that the finished product is safe to be comercialised, ie consumed.

 

If above deduction is correct, then AFAIK, a positive product release form would essentially require 1 line of an Excel sheet to formally document what you are currently already doing, eg via reference to dates, records for lots in shipments, MD scans, signing-off. A date column obviously enables multiplicity although IMEX some people prefer individualization so as to generate "lot" FS packages.

 

Wonderful that life can be so simple, many people will envy you. :smile:

 

Rgds / Charles.C

 

PS - but no "easy" way AFAIK to document shipments from highly mixed lots without electronic assistance.


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Charles.C


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#4 fgjuadi

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Posted 13 August 2014 - 10:20 AM

Our only food safety CCP is the metal detector.  We are working toward using sensory panels as a QCP.   My employees sign off on their metal detector checks every 30 min & I review and sign off at the end of a batch or the next day, and that form has dates, product, etc, but the problem is communicating that review to the shipping office.  How do they know it's okay?  Like, physically? An Excel sheet on the shared drive they check for the lots I've reviewed as below?

 

12/12/2012 - Lot 8675309 - Good to go, JimBob. Send 'er out - MM

 

 

  I know we don't even pack truffles until I give the okay - but the bars are a different story.  The wrapping happens in-line, plus WIP and remelt lots have to be checked -   Shipping works from order number while I work from lot / batch number. 


Edited by magenta_majors, 13 August 2014 - 10:35 AM.

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#5 Charles.C

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Posted 13 August 2014 - 01:20 PM

Dear magenta_m,

 

If you are trying to present the case for a digital "overseer", it's just preaching to the converted. :smile:

 

One shipment inspection involving sampling lot codes from container loads at a totally computerized, multi-level, frozen cold storage facility convinced me for all time. Unfortunately the investment/running costs were equally mindblowing. :smile:

 

Just like pizza drones, but on rails.

 

Rgds / Charles.C


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Charles.C


#6 ChocolatesMyGame

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Posted 13 August 2014 - 01:39 PM

Hi Charles,

 

Unfortunately, life isn't that simple here.  This just happens to be the beginning point of a long journey towards certification.  Eventually I will be requiring 2 CCPs, at least 1 regulatory requirement (retail weights), and sensory be met prior to release of our product.  Production and I did recommend a simple procedure of posting the  last acceptable lot code on a board in the warehouse for shipping to verify prior to picking product, but the warehouse manager said he felt that his people would not be able to 100% adhere to it.  I don't understand why, but this is where I'm stuck.  I'm pushing upper management to get us a new electronic system and I seem to have some buy-in so I'm keeping my fingers crossed.  Until then any suggestions are welcome!


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#7 Charles.C

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Posted 13 August 2014 - 02:04 PM

Hi Charles,

 

Unfortunately, life isn't that simple here.  This just happens to be the beginning point of a long journey towards certification.  Eventually I will be requiring 2 CCPs, at least 1 regulatory requirement (retail weights), and sensory be met prior to release of our product.  Production and I did recommend a simple procedure of posting the  last acceptable lot code on a board in the warehouse for shipping to verify prior to picking product, but the warehouse manager said he felt that his people would not be able to 100% adhere to it.  I don't understand why, but this is where I'm stuck.  I'm pushing upper management to get us a new electronic system and I seem to have some buy-in so I'm keeping my fingers crossed.  Until then any suggestions are welcome!

Dear CMG,

 

I am fascinated by yr CCP for retail weight.

May I enquire what is the health risk associated with short or over weight - nutritiional deficiency?, shopping rage ? (In olden times would have slipped into HACCP / Economic Hazard Analysis but I thought that was long gone?)

 

i suspect yr Warehouse Manager has been "here" before and can see some risk of serious s*** dropping on his uppers. :smile:   Probably a useful ally for sucking up to. :smile:

 

Rgds / Charles.C


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Charles.C


#8 Snookie

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Posted 13 August 2014 - 04:28 PM

Dear CMG,

 

I am fascinated by yr CCP for retail weight.

May I enquire what is the health risk associated with short or over weight - nutritiional deficiency?, shopping rage ? (In olden times would have slipped into HACCP / Economic Hazard Analysis but I thought that was long gone?)

 

i suspect yr Warehouse Manager has been "here" before and can see some risk of serious s*** dropping on his uppers. :smile:   Probably a useful ally for sucking up to. :smile:

 

Rgds / Charles.C

 

I read that as 2 CCP's and a regulatory requirement the retail weight.  While not a health issue yet....the fines for being underweight can be huge.  There is current discussion that a product being off weight also effects the calorie count and nutritional values, but don't think that one has been implemented, although have not paid close attention to that one as have been distracted by other things. 


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#9 ChocolatesMyGame

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Posted 13 August 2014 - 04:41 PM

Yes, Snookie is correct.  Retail weights are not a CCP, but must adhere to FDA regulations in that we can not have product weighing less than the MAV (maximum allowable variation).  Our 2 CCPs I am referring to are Metal Detection and Allergen Declarations on packaging. Apologies if my post was not completely clear.

 

However, I find "shopping rage" quite amusing!


Edited by ChocolatesMyGame, 13 August 2014 - 04:42 PM.

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#10 Snookie

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Posted 13 August 2014 - 06:25 PM

underweight chocolate could definitely induce a shopping rage :rofl2:  :rofl2::roflmao:  


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#11 Charles.C

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Posted 13 August 2014 - 06:28 PM

Dear CMG,

 

No problem, in truth the error was more on my side. Was multi-tasking at the time (ie watching TV). :smile:

 

TBH, I didn't realize FDA controlled the Weight as well as Quality legislatory issues.

 

Rgds / Charles.C


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Charles.C






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