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#1 Officer

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Posted 25 October 2017 - 08:50 PM

Hi,

 

I'm in the process of currently updating my companies HACCP plan.

 

The current layout seems to be killing a lot of forests and from my perspective could be consolidated quite easily.

We're a bakery/patisserie that produces a number of different product. 9 quiche, 7 pies and 8 shells; 4 baked and 4 unbaked, these don't include size variation from 1.5" through to 10" 

 

I've looked around and can't find any topics on the layout of the plan itself so here I am.

 

 

 

The three obvious layout plans I can see are as follows:

 

Each product (all 24) get their own Plan, HACCP Forms 1 - 10 - this is the current layout and there's a huge number of double ups as all quiche forms 3, 4, 5, 6, 7, 8, 9, and 10 are the same with a small difference in the named ingredient such as Ham, Bacon, Asparagus etc... and the same goes for pies and shells 

 

My next options are:

 

Layout based on Form order as such; ALL Form 1's then ALL Form 2's then ALL form 3's .... this wold be consolidated from forms 3 on wards as they products are so similar in production process and hazards. Obviously this raises the issue of having to flick backward and forwards through for each product if you're wanting to follow Form 1 -> 10 for one product

 

to further improve on this I believe the best layout would be

 

All Forms 1 -> 10 for Quiche, then all Forms 1 -> 10 for Pies as another section, and lastly the shells Form 1->10 as the last section.

 

 

 

So I guess my question is, are there rules on the layout, if so how flexible are they and are they open to interpretation?

 

None of these really lower the required work other than one creating a lot more copy and pasting than the others...

 

Hopefully the question is clear, and if it makes a difference I'm based in Canada.

 

 

Thanks

 


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#2 Madam A. D-tor

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Posted 25 October 2017 - 09:13 PM

Dear Officer,

 

I am not quite sure what you mean by form 1 to 10.

Perhaps you can post your table of content.


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Madam A. D-tor

#3 Officer

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Posted 25 October 2017 - 09:32 PM

Sorry, please see below:

 

 

The FSEP-HACCP Plan forms are:

  • Form 1: Product Description
  • Form 2: List of Product Ingredients and Incoming Material
  • Form 3: Process Flow Diagram
  • Form 4: Plant Schematic
  • Form 5: Biological Hazard Identification
  • Form 6: Chemical Hazard Identification
  • Form 7: Physical Hazard Identification
  • Form 8: Decision Tree - CCP determination and other Control Measures (PP, PC)
  • Form 9: Hazards Not Controlled by the establishment
  • Form 10: Critical Control Point(s)
  • Form 11: Process Control(s), when applicable

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#4 Madam A. D-tor

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Posted 25 October 2017 - 10:18 PM

Dear Officer,

 

 

As far as I know there are no rules for HACCP layout. (of course everything need to be in there and it must be clear and understandable). 

 

in general your lay out is fine. The problem is that you seem to have a HACCP plan for each and every product. This makes it a hell to keep it all actual and up to date.

 

The best thing I can suggest you, is to work with product groups. Following your information your groups might be quiche baked, quiche unbaked, pie baked, pie unbaked, shell baked and shell unbaked. There might be more or less. Group your products based on processes, intended use, ingredients. Maybe it is relevant to have group quiche made with raw meat and quiche without raw meat.

 

I would make 1 HACCP manual for all identified product groups. Actually this is how you suggested it.

  • Form 1: Product Description
  • 1.1 product group 1
  • 1.2 product group 2
  • 1.3 product grou p3 etc
  • Form 2: List of Product Ingredients and Incoming Material
  • (make clear reference which ingredients belong to which product (group)
  • Form 3: Process Flow Diagram
  • 3.0 general flow (to provide general overview and provide overview of cohesion and relation ship between the processes)
  • 3.1 reception/storage
  • 3.2 production product group 1
  • 3.3 production product group 2
  • 3.4 production product group 3
  • etc
  • 3.xx storage, dispatch and transport
  • (beside reception/ storage and dispatch and transport there might be more processes that are similar/comparable to all product groups. Might be preparation process (mixing dough, preparing ingredients) and packing process. Takes these general processes out of the specific flows for the product groups.
  • Form 4: Plant Schematic
  • Form 5: Biological Hazard Identification
  • Form 6: Chemical Hazard Identification
  • Form 7: Physical Hazard Identification
  • Form 5, 6, 7 might be done in one. You than need to make clear if the hazard is biological, chemical or physical. Perform the hazard identification (and later the risk assessment) for each process flow.
  • 5 hazard identification raw materials
  • 6 hazard identification general process and prerequisite programs
  • 7.1 hazard identification reception/storage
  • 7.2 hazard identification production product group
  • 7.3 hazard identification production product group 2
  • 7.4 hazard identification production product group 3 etc
  • Form 8: Decision Tree - CCP determination and other Control Measures (PP, PC)
  • Form 9: Hazards Not Controlled by the establishment
  • (I hope this is an empty document)
  • Form 10: Critical Control Point(s)
  • Form 11: Process Control(s), when applicable

(above is just a suggestion, it will save some trees)

 

Remark: In your HACCP plan I am missing: HACCP team (description, expected knowledge and experience, and persons in it), description of the systematics used, validation of CCPs and verification processes.

 

Good luck with changing your system.

N.B. If you want to save more trees --> just keep it all digital and do not print it.


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Madam A. D-tor

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#5 Officer

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Posted 25 October 2017 - 10:47 PM

Thanks for the detailed answer.

 

You've backed up and confirmed exactly what I was looking at doing, I just wanted and need some clarification before committing.

 

As for keeping it Digital, I'd love to and hopefully by the time I've finished simplifying everything the company will see no need to keep paper copies.

 

 

On a side note, is there any issue keeping logs and records digitally? So much paper is wasted at the facility.


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