5 replies to this topic

[Mandark]

Hi, 

 

Can we merge 3 haccp plans into 1 manual? Currently 3 manuals or plans for the following products: Canned sardines, pouched sardines and bottled sardines. The process is same from receiving of fish to cleaning and metal detection however the packaging on each product type is different, sterilization is water spray for pouched and bottled, while canned is steam. 

 

Regards, 

Mandark

[Charles.C]

Hi, 

 

Can we merge 3 haccp plans into 1 manual? Currently 3 manuals or plans for the following products: Canned sardines, pouched sardines and bottled sardines. The process is same from receiving of fish to cleaning and metal detection however the packaging on each product type is different, sterilization is water spray for pouched and bottled, while canned is steam. 

 

Regards, 

Mandark

The flowcharts and CCPs are presumably significantly different. Makes merging into one haccp plan difficult IMO.

 

No problem to have 3 plans in one manual though. IMEX this is the usual set-up.

[Miss Frankie]

It can be done!
When I started here in December, I found 1 flowchart for ALL of our products.  We have 3 basic products (1 in packaged in different size containers, but the process is the same)  I don't know who initially designed the flow chart, but it was difficult to follow. 
What I did was redesign it, color coded each CCP type (biological, physical, & chemical)  then make a key for each product.  
Since each step was numbers, the key lists the numbers in order for each different product.

For example, the process for all products is the same steps 1 - 10, the product A is 11,12,16,18,23,24,25,26,30,31,32

product B is 11,13,16,18,25,26,31,32, etc.

 

I completed this the day before our recent USDC audit, and our auditor LOVED it.  He said he was mad that he hadn't thought of it before, and was going to suggest it to  other companies.

 

It can be done!  
 

[Kara S.]

Yes, grouping of like product types is allowed. It's based on your preference and what is easiest to maintain at your facility.

As you start the process, you may find that Charles is correct. You get to that point in the process flow where it branches off and there are too many differences to address. But if you are already thinking you can combine them, you most likely can without issue.

It's just important after a big change like that to verify everything. There could be copy/paste errors, or forgetting to transfer something over.

[Scampi]

If your company is wiling to spend the money, Microsoft Visio will be your best friend for the flow chart as it is intuitive and allows you to drag and drop and the arrows will realign themselves

 

Keep your current plan as is (i.e. don't archive it yet) until your new combined plan is ready to go

 

Make sure to  walk the floor with the flow chart more than once to ensure you've captured everything correctly

 

Review, review, review

[Scotty_SQF]

Agree with Scampi on Visio.  It is an awesome tool for making charts.  I have also seen it done where there is one flow chart for the combined process and then separate flow charts for the packaging end that show each different packaging process.  As others have said, it is up to you and what works best for your facility and as everyone else has said, review, walk the steps again and review before putting in place.