I am a QA in a food service (bakery products) factory in the UK.
We produce cakes for a high street coffee chain, as well as a few supermarkets etc.
We are having the same issues all the time with regards to traceability.
I have a few questions and I'm looking for any or all advice you can offer me!
1. How do you make employees (especially those responsible for recording information for traceability) care enough to record them correctly?
2. Does anyone have an example of a 'team briefing' or some kind of training which can be used? I'm not sure the employees all actually understand that its not just stock control/costing etc. Its a food safety issue which could mean the difference between a huge recall which would affect our staff numbers etc due to the cost, or a small stock return of one batch from our external warehouse facility (costing almost £0 and a minor inconvenience)...
3. How do I or how could I check and document that all information written on mixing sheets etc is correct during a production run? How do you do it?
Here's a description of our process flow and current procedure:
1. GOODS IN- stock either arrives direct from supplier (egg etc which is in smaller batches), or from our offsite warehouse storage facility (used for multiple companies/sites within our food 'group'), regardless of where the stock physically arrives, we get a delivery note on the day it is delivered to 'us' (onsite or off). A GRN (goods received number) is generated in the format of DD-MM-YYYY-# (where # is the pallet number of each day- IE. if 8 pallets delivered in one day its DD-MM-YYYY-1 up to DD-MM-YYYY-8).
2. Sticky labels are printed out with Item Code (a 5 digit number corresponding to ingredient, for example egg 70027), GRN (IE 24-07-2016-2) and BB or use by date (ie 31-07-2016). They are then stuck to or left on the pallet of goods, and applied (supposed to be anyway!) to each box or bag as its removed from warehouse.
3. Stock is requisitioned by production/mixing dept, a 'Raw Material Movement' document in warehouse is filled in with all info for each ingredient- date/ingredient name/Item Code/amount/GRN/BB date and signed by stores man and whoever is removing the stock.
4. Stock is taken (with its GRN labels for each box or bag) to debox area to be decanted into ingredient tubs and passed over to production/mixing by the 'deboxer' with the corresponding GRN label and info. The deboxer has a raw material movement sheet to document what gets passed to mixers, what is stored in ingredient tubs in debox area, and what is returned to warehouse.
5. When the mixers get their ingredients for each batch made, the recipe document has spaces to record the time of each batch produced, GRN and BB date of each ingredient and blank spaces for instances where more than one GRN of an ingredient is used (I DON'T think they pay enough attention and/or always record or notice a change of GRN.
6. Our con bar line operators also have process control sheets which have the time, batch # used, GRN's and BB dates of raw materials.
Does anyone have any advice or suggestions to help have this process done correctly/completely or changes to make it more effective etc?
Thanks and sorry for the long post!