Internal Audit Corrective Action and Root Cause

During food safety internal audit, Found some non conformities which is

1.Tape used as a temporary fix to part of the hydrail conveyor
2.On the re-freeze line was observed loose hanger above the shaker
3.Flaking paint over the product
4. Loose tape found on pipe above product zone.
5. Some hard to reach areas in the bucket conveyor and other equipment has some product residue observed during the pre-op check

6.Knives are not controlled.

kindly tell me what will be the corrective action to prevent reoccurrence

 

Thank you in advance!

Fire maintenance manager would be my first instinct.

Fire maintenance manager would be my first instinct.

 

:roflmao: Seriously though.....before pulling trigger......I have seen some creative production people help maintenance and not let them know about some of their fixes (flaking paint aside). 

:giggle: @ fire Maintenance Manager. 

 

You can try implementing a pre-op inspection before production and retraining of personnel.   These problems should of been picked up during monthly inspections as well, may want to add that to your audits.  I used that for my CAR and it worked out well.

This is how my company would address nonconformances:

     Corrective Action = fix it for now.

     Preventative Action = fix the system so it doesn't happen again.

 

Preventative Action could include training (no tape allowed), audits, etc.  You have to make sure the new system elements are in place, are being followed, and are making an improvement (audit findings show less nonconformances each time).

During food safety internal audit, Found some non conformities which is

1.Tape used as a temporary fix to part of the hydrail conveyor
2.On the re-freeze line was observed loose hanger above the shaker
3.Flaking paint over the product
4. Loose tape found on pipe above product zone.
5. Some hard to reach areas in the bucket conveyor and other equipment has some product residue observed during the pre-op check

6.Knives are not controlled.

kindly tell me what will be the corrective action to prevent reoccurrence

 

Thank you in advance!

Dear hmacdonald,

 

(1) Purchase a Kevlar QA uniform.

 

(2) Give Production Manager (and QA?) a textboook on Food GMP and/or a copy of FSEP.

 

(3) Introduce videos in yr Training course. Spy camera ?

 

Rgds / Charles.C

For number 6, you can also include inventory of knives as one of your controls. We also do that in our plant.
:shades:

For number 6, you can also include inventory of knives as one of your controls. We also do that in our plant.
:shades:

 

 

Maddox- do you have a procedure for knives and also could you send me a sample document of inventory of knives, thank you in advance

During food safety internal audit Found some non conformities which is

1.Tape used as a temporary fix to part of the hydrail conveyor
2.On the re-freeze line was observed loose hanger above the shaker
3.Flaking paint over the product
4. Loose tape found on pipe above product zone.
5. Some hard to reach areas in the bucket conveyor and other equipment has some product residue observed during the pre-op check
6.Knives are not controlled.

kindly tell me what will be the corrective action to prevent reoccurrence

Thank you in advance!

For 1., 4.) If you dont already have one, you might want to write up a Temporary repair policy stating what can and cant be used for temporary repairs. (Tape, String, Wire, Cardboard......) and then retrain the maintenance crew on this procedure.

For 2., 3., 5) May want to take some picture of these and include them in your GMP and Sanitation trainings. Giving the employees real life examples to look at helps them get a better understanding.

and for #6 i agree with Maddox : Write up a policy for knife/blade control and keep an inventory of them to inspect against.

This is how my company would address nonconformances:

     Corrective Action = fix it for now.

     Preventative Action = fix the system so it doesn't happen again.

 

Preventative Action could include training (no tape allowed), audits, etc. 

 

Indeed and although basically the same thing PA seems to be a less popular term these days I see 'elimination of the root cause' a lot more, possibly because it implies more effective action!?

 

Regards,

 

Tony

I would also indicate an increase in the rigour and frequency of the PRP verifications - worked well for my company when we had the food safety team members take on the task by turns

Thank you so much for your advice.

 

 

 

11.7.5.3 – Temporary Fasteners, tape on the equipment

It appears to be an ongoing problem that continues. can you help me identify the root cause please thank you

 

 

It appears from the information presented there are issues with:

 

Temporary repair program.

Preventive Manitenance Program

SSOPs

PRP - knife control.

 

Root cause must be determined for each finding prior to determining corrective action. Some possibilities:

 

Systems not in place or do not address issues leading to the findings.

Systems in place but employee training is abscent or ineffective.

Employees trained but not following systems.

 

On the bright side:

Your internal audits are identifying nonconformities.

The pre-ops are catching cleaning deficiencies.

 

Bottom line is you know your facility & programs, a good root cause analysis around the programs that should be controlling the audit findings will inform your corrective actions.

Thank you for all your help