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Quality metrics: KPIs

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Posted 15 December 2016 - 07:15 PM

Fellow IFSQN colleagues,


There are lots of articles and literature about quality metrics which can be measured in a food processing plant. Costs of quality, Overall Equipment Effectiveness (OEE), percentage of products in compliance, on time and complete shipments, customer complaints & new products introduction (NPI).


Apart from costs of quality, we track and trend the rest of the metrics. Anybody here familiar with any other Quality or Food safety metrics which are being measured? How do you measure and report them?


Thinking about expanding our key performance indicators (KPIs) with a special focus on quality and food safety metrics.


Thank you.


Ryan M.

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Posted 15 December 2016 - 10:13 PM

Hello Mambo,


We track a number of KPI's for our operation, ultra-pasteurized fluid products (dairy and non-dairy).  We are a new startup, so it is critically important to track these numbers and make sure we are progressing forward.  Here is what we track thus far:


  • Lab Hours (convert to a cost per unit and per gallon packaged)
  • Defective Product %
  • Plant Rerun %
  • Units Placed on Hold
  • Audit Compliance
  • First Pass Quality (finished product passing all quality specs in the first testing)
  • Finished Product Keeping Quality % (finished product sensory conducted 10 days past shelf-life and scored against gold standard)
  • Environmental Monitoring Compliance (Air, Water, Micro swab testing, Pathogen swab testing)
  • Finished Product Component Average, deviation from the target % (this is important for us in terms of fat and solids loss for our dairy and non-dairy fluids)

I have incorporate the last two just yet, but am working on it.  Another item I want to incorporate which you may find helpful is a KPI around the facility self-inspections (GMP or Audits) such as average days to complete corrections/corrective actions or percent completed within 30 days.


I hope that helps.



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Posted 16 December 2016 - 10:26 PM

In addition to the above, tracking corrective action compliance (for everything from pest control to internal audits to supplier adherance to specifications), master sanitation completion and preventive maintenance are quite helpful to show sanitation and maintenance needs.

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