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How many Non-conformances did you get at your last audit?


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Poll: GFSI Audit Nonconformities (674 member(s) have cast votes)

How many NC’s did you get at your last audit?

  1. 0 (40 votes [5.93%])

    Percentage of vote: 5.93%

  2. 5 or less (379 votes [56.23%])

    Percentage of vote: 56.23%

  3. 6 to 10 (183 votes [27.15%])

    Percentage of vote: 27.15%

  4. More than 11 (72 votes [10.68%])

    Percentage of vote: 10.68%

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#26 Marshenko

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Posted 30 July 2019 - 02:01 PM

I never allow any types of caps or hats in my facility. If you need to wear one, cool. just wear it outside and not indoors.

 

I've mostly worked in production environments where the temperatures are kept at 40F and below, or 10F and below in the freezers.  Baseball and knit caps can keep people from quitting.  At one place, I was actually given enough leeway to work out a deal with our uniform service to purchase and have knit caps washed with our smocks, aprons, towels and gloves, which was fabulous.



#27 LDG_Honey

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Posted 30 July 2019 - 02:37 PM

SQF audit with a score of 87.

13 Minor NC were found.

 

They mostly fame from failure to properly update from SQF 7.2 to SQF 8

 

The previous QA manager left due to personal conflict with another employee.

It took 7 months to find a suitable replacement (me).

 

 

I had 2 months to learn the whole system, undo the mistakes that were made before I came, learn the job and try to update our system to SQF 8.



#28 The Food Scientist

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Posted 30 July 2019 - 03:02 PM

I've mostly worked in production environments where the temperatures are kept at 40F and below, or 10F and below in the freezers.  Baseball and knit caps can keep people from quitting.  At one place, I was actually given enough leeway to work out a deal with our uniform service to purchase and have knit caps washed with our smocks, aprons, towels and gloves, which was fabulous.

 

I agree with you since that is a totally different environment! Gotta keep your employees warm :) 


Everything in food is science. The only subjective part is when you eat it. - Alton Brown.


#29 Marshenko

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Posted 30 July 2019 - 03:08 PM

I agree with you since that is a totally different environment! Gotta keep your employees warm :) 

 

I always tell people to dress in layers - you can always take stuff off if you get too hot, but you can't put on something you don't bring with you.  I've had more than one new person walk out during first break and never return!



#30 AC2018

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Posted 31 July 2019 - 01:54 PM

SQF (Unannounced) Category 19

 

96 pts. - 4 minor non-conformance's

 

1. Did not perform a food defense 'challenge'. Didn't realize a challenge was different than a review/inspection which we already do. 

2. Needed to expand on our food fraud mitigation plan. Pieces were there but missing some parts. 

3. Didn't have a written procedure for purchasing new equipment including what standards are required, written manager sign off, etc. 

4. Did not have included in our disposal policy something specifically stating how we would dispose of trademarked items. 



#31 Adolf von Liebenberg

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Posted 31 July 2019 - 02:04 PM

BRC AA - 4 minors



#32 greta

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Posted 31 July 2019 - 03:19 PM

BRC (V8) 4 minors, grade AA

 



#33 Linda Phillips

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Posted 31 July 2019 - 06:45 PM

We received 1 Non-Conformance during our SQF Audit in June in section 2.2.3.2 Document Control / The auditor stated that there was evidence of write-overs making data illegible on records reviewed



#34 Sweet'n'low

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Posted 31 July 2019 - 07:19 PM

How do you all feel about hairnets being replaced after employees either exit the site for a smoke break and/or restroom break? I expected my employees to change hairnets if they left the production area. I was told that was too strict. I tried to compromise with if employees go outside or visit the bathroom, they are to change their hairnets. Management agreed, but never enforced it. Employees get annoyed when I tell them to change it and make the comparison to their clothing as a way to not have to change their hairnets. Thoughts on the matter? 

 

P.S. management still doesn't enforce the changing of hairnets after a year ago where the decision was made. 



#35 zanorias

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Posted 01 August 2019 - 12:52 PM

How do you all feel about hairnets being replaced after employees either exit the site for a smoke break and/or restroom break? I expected my employees to change hairnets if they left the production area. I was told that was too strict. I tried to compromise with if employees go outside or visit the bathroom, they are to change their hairnets. Management agreed, but never enforced it. Employees get annoyed when I tell them to change it and make the comparison to their clothing as a way to not have to change their hairnets. Thoughts on the matter? 

 

P.S. management still doesn't enforce the changing of hairnets after a year ago where the decision was made. 

 

I insist on employees disposing of their hairnet on exit and putting on a new clean one on entry to the production area. Otherwise it's just one more potential for introducing contamination. I agree with you personally, though sounds as though your management does not, so a bit of an uphill battle for you unfortunately :headhurts:



#36 Sweet'n'low

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Posted 01 August 2019 - 01:17 PM

I insist on employees disposing of their hairnet on exit and putting on a new clean one on entry to the production area. Otherwise it's just one more potential for introducing contamination. I agree with you personally, though sounds as though your management does not, so a bit of an uphill battle for you unfortunately :headhurts:

Well, every time I see it, I make sure they change hairnets. If others were to enforce it, we would end up running out due to one employee constantly taking unscheduled smoke breaks (around 17) between 7am and 12pm lunch break. I think we have bigger issues.  :oops2:



#37 DN_QAMGR

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Posted 02 August 2019 - 04:44 PM

5 or Less - BRC Packaging Audit - (5 Years) - AA 

 

Minors but consistent issues: 

 

1. GMP violations

a. Including Food and Drinks 

b. Food in lockers

c. Trip hazards

d. Pallet/storage areas

e. pallet conditions

 

2. Razor blades

a. safety hazards

b. food safety foreign object hazards

 

3.  Documentation and verification

a. Supervisor sign off

b. Consistency in documentation (all depts)

 

So, these are my major issues that I've observed every year, even though the auditor found it as minors. In my past companies, it seems to vary with the type of issues that consistently occur. Working for a smaller company, I realize that if there isn't enforcement by Senior Management and training by educating employees why these are required, it makes it difficult for Quality Assurance & Control to manage the Food Safety, Quality and Legality for my company. 

 

In our field, I guess these are the daily challenges that we encounter. Eventually everyone must learn this, so be optimistic and diligent! (and make sure you don't release bad product)

 

have a good one everyone!



#38 PollyKBD

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Posted 08 August 2019 - 02:33 PM

SQF in April, score: 95 

 

Was my first sqf audit. Next year is unannounced! Is it bad that I'm nervous already? 

I feel ya. My very first SQF audit was last year, I have 1.5 months experience and we scored a 97, this year was my 2nd and it was unannounced. I made sure my ducks were in a row right before the window and held on. They came a week after our anniversary date, we were on pins and needles the whole month before they came. We scored a 96 this time due to much growth within the company. We went from 12 employees to 35+ in 1 year. I'm proud of that 96 and what we've been able to accomplish in such a short time and small space.

In other words, I can't tell you not to worry, but I can tell you that you have a year to prepare, you already have the foundation, and you are going to be just fine.



#39 solrac

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Posted 08 August 2019 - 02:46 PM

SQF in April, score: 95 

 

Was my first sqf audit. Next year is unannounced! Is it bad that I'm nervous already? 

Hello.

 

Our window date for our unannounced audit is almost 2 months. In your case, when the auditor showed up to conduct the audit? Thanks



#40 PollyKBD

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Posted 08 August 2019 - 02:48 PM

I never allow any types of caps or hats in my facility. If you need to wear one, cool. just wear it outside and not indoors.

The only hats we allow are beanies and they must be completely covered with a hairnet. Even if you put a hairnet over a baseball cap there is still exposed hat. Our employees don't have a problem with our hat policy, but contractors like to argue when they come in the building. 



#41 PollyKBD

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Posted 08 August 2019 - 02:57 PM

Hello.

 

Our window date for our unannounced audit is almost 2 months. In your case, when the auditor showed up to conduct the audit? Thanks

Yes, it's a 2 month window, 30 days before the anniversary date through 30 days after. Our anniversary date is June 20, they showed up July 1 (or maybe July 2- right before a holiday!)

I made sure we were prepared for a May 20 arrival and then continued to monitor so we didn't have any slip ups. I actually liked the unannounced because it kept everyone behaving the way they should always behave. My only issue was that we have so many new employees, training makes me nervous. Always have to make sure they start off with good habits.



#42 solrac

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Posted 08 August 2019 - 03:24 PM

Yes, it's a 2 month window, 30 days before the anniversary date through 30 days after. Our anniversary date is June 20, they showed up July 1 (or maybe July 2- right before a holiday!)

I made sure we were prepared for a May 20 arrival and then continued to monitor so we didn't have any slip ups. I actually liked the unannounced because it kept everyone behaving the way they should always behave. My only issue was that we have so many new employees, training makes me nervous. Always have to make sure they start off with good habits.

I am planning to be ready one month before our anniversary date. Same as you, as early now, I feel nervous!



#43 bakeryscience

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Posted 08 August 2019 - 03:36 PM

Does anyone have any advice or tips on handling the anxiety? I struggle with it already and we aren't even GFSI yet...I am going to be a nervous wreck once we have our first SQF audit!



#44 Pepperfire

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Posted 08 August 2019 - 04:51 PM

We are benchmarking FSSC22000:2005

It is a ton of work and with the exception of my External Auditor, I am doing this all by my lonesome. Ours was my first official audit, so I felt pretty good with these results after three years of training and work:
 

Critical nonconformities: (0)

Major nonconformities: (1)

The organization has not completed a full hazard analysis that addresses all the hazards identified during the preliminary hazard analysis.

Minor nonconformities: (1)

The organization has not completed all the documentation necessary to conform to FSSC 22000 –

  1. Emergency Preparedness and Response Manual

  2. The PRP Program is still in development and incomplete; additionally, specified responsibilities have not been assigned yet (generic “position x” is used throughout the document while being written), although conformance to the requirements was in evidence during the audit.

  3. Hazard Analysis and associated Flow Diagram

Areas of concerns (stage 1 only)



#45 Pepperfire

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Posted 08 August 2019 - 04:54 PM

Does anyone have any advice or tips on handling the anxiety? I struggle with it already and we aren't even GFSI yet...I am going to be a nervous wreck once we have our first SQF audit!

I was really (and I mean really) nervous for my first audit, and worse, I have Aspergers syndrome. I feel like I will never succeed in getting our Cert. I am benchmarking FSSC 22000.

Some thoughts that will help you until you have the final auditor's report in hand...

BREATHE, nobody is going to fire you for not getting 100%
BREATHE, you have time to Kaizen and complete ALL nonconformities before anyone will shut you down.
BREATHE, You can't possibly be any more anxious than I am... I own the place. I get shut down, not only am I out of business, so are 10 employees. :)

You'll be fine. <3



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#46 terris

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Posted 08 August 2019 - 06:07 PM

SQF Edition 8, 3 minor NCs. Bottle of ibuprofen in maintenance room, annual calibration missed on a thermometer and food contact tubs used by maintenance to store stuff in. 



#47 nellieonacherry

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Posted 09 August 2019 - 10:35 AM

SALSA Standard (Recommended with no Action Plan required)



#48 zanorias

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Posted 13 August 2019 - 07:02 AM

Does anyone have any advice or tips on handling the anxiety? I struggle with it already and we aren't even GFSI yet...I am going to be a nervous wreck once we have our first SQF audit!

 

Running a mock audit or two may be worth consideration. Not only will it help you get a feel for the actual audit experience but you may find some things highlighted by the auditor that you weren't aware of, and can action before the real audit.



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#49 aureliew

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Posted 13 August 2019 - 03:01 PM

BRC V7 announced - last year: 4 minors AA achieved

- not stating on visitor sign in that we were a nut free site

- small hole in fabric (internal wall)

- small hole in fabric (external wall, interim maintenance)

- one bag not closed properly

 

Awaiting my first FSSC22000 (new company).

 

Aurélie 



#50 Heidi_SQF

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Posted 13 August 2019 - 04:55 PM

SQF 8.0 Food Safety Code for Manufacture of Food Packaging

 

5 minor NCs - this was our unannounced audit year






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