Pooling water in dry goods - audit non-conformance

I need help closing a non-conformance from a supplier assurance audit.

NC- Pooling water was observed in the dry storage area. The pallet with dry materials was sitting in the pooling water.

This is what I have so far;

Root cause: The root cause of the pooling water is not known. This is not an area where pooling water is regularly observed (i.e., our trend analysis does not suggest the root cause is related to any internal activities). However, on the day of the audit, contractors were performing preventative maintenance on the air compressor which is located in close proximity to where the pooling water was found. We suspect that the pooling water was a result of the maintenance being performed on the air compressor. The HACCP coordinator is responsible for inspecting the floors for evidence of pooling water during the pre-operational inspection and once again mid-day during the daily production inspection. The HACCP Coordinator failed to identify the pooling water on the day of the audit.

Corrective Actions: Vacuum pumped the water. Re-trained HACCP Coordinator on Pre-Operational Inspection & Hygiene Code

Procedure and Production Inspection Procedure.

Preventative Actions: ???    I’m thinking in the future accompany contractors when they are preforming service. But what procedure would that belong on? Any other thoughts?

I’m open to any feedback, I’m looking to learn.

Thanks 

Maintenance: after-maintenance cleaning procedure (whoever's doing maintenance is responsible for leaving maintenance area and equipment clean (e.g. no pooling water, no debris, wires, tapes, no instruments left, etc.) QA is responsible for observing area and equipment after maintenance is finished.)

I agree with the previous response:  Maintenance: after-maintenance cleaning procedure (whoever's doing maintenance is responsible for leaving maintenance area and equipment clean (e.g. no pooling water, no debris, wires, tapes, no instruments left, etc.) QA is responsible for observing area and equipment after maintenance is finished.).  However, you may want to state: Our corrective action, after maintenance has completed task, we will have sanitation complete a deep clean and remove any water that may have formed from maintenance.   There will be a sign off sheet to verify that the task has been completed and verified by our QA team

I agree with Olena, it's probably a shared responsibility.

What does "pooling water" mean, 0.1 inch, 6 inches ? (contacts materials, etc etc ?)

Documentation of Contractual Working / Environment ?

Haccp/QA operational team a one-man show, ie the HACCP Coordinator ? (relates to "failed to identify")

PS - overlapped previous Post

Thanks for the responses. 

HACCP/QA is only one person. We are a small facility. We don't have sanitation during the day. We have a 3rd party sanitation team come overnight to clean. 

The pooling water was maybe half an inch. 

So if I'm understanding correctly, I could create an after maintenance cleaning procedure? Or maybe a procedure on how how we handle contractural workers? 

ntay96, yes to what you said

but also train your maintenance lead (if you have one, plant manager if not)

You might also want to include that all 3rd party contractors leave the area like it was when they found it, and request someone move product if required, so part of the root cause may be not having a 3rd party contractor agreement process in place

ntay96- for your maintenance procedure it can be fairly simple given the information you have given. When I sat down with the maintenance crew and explained what we needed to do to achieve SQF we came up with a Work Order Procedure and it seemed to work quite well. I am sure your maintenance department already tracks what is repaired, on the end of that sheet you can add something to the effect of:

All product contact surfaces and surrounding areas are clean and pose no risk to food safety ___

All tools, equipment and materials are accounted for ______

Released to production _____

Checked off and signed by QC personnel not Maintenance. I had QC personnel and Maintenance sign off on a page as read and trained and kept in in the training jacket. This would cover you for 3rd party contractors as well as your inhouse employees would sign off on cleanliness and release to production.

Anyways just a suggestion that has worked well and might be useful for you.

I went through a similar situation, and this is what I came up with. This form gets filled out after any maintenance activities.

I went through a similar situation, and this is what I came up with. This form gets filled out after any maintenance activities.

Hi ABFC,

Thanks for the nice document.

I deduce the Chef has no QC (or is the QC).

Just to nitpick/consistency, I suggest the last 2 "Are"s in your attachment should be "Were"s.

Do you have a schedule that you use for Preventative Maintenance?  In addition to Task, Frequency, Responsibility, Date Performed, and Overseen By, my PM Schedule has a line item for: Passed Post-Maintenance Inspection* (y/n).  With the note: *When applicable, Post-Maintenance Inspection includes removal of tools and debris and/or cleaning and sanitization.  This acts as a reminder for employees to check areas after work has been completed, and a way to document those checks.  We use this is for maintenance performed internally and by third party service providers.

Hi ABFC,

 

Thanks for the nice document.

I deduce the Chef has no QC (or is the QC).

Just to nitpick/consistency, I suggest the last 2 "Are"s in your attachment should be "Were"s.

Eww now that you mentioned that I can't unsee it. I agree and I am not sure why I chose to use "Are" in those spots. Just fixed it now.