Foreign body reduction plan

I've just been asked by one of my customers to develop a "Foreign Body Reduction Plan" , based on CPMU, and to be honest, I'm at a loss

I had 2 complaints last year for foreign bodies in our products, my CPMU was for last year less than 0.004,  and I realise my reduction should be to get zero! but how the hell do I develop a plan?

Be far easier if I had loads of FB complaints!

Any suggestions welcome

Caz x

I've just been asked by one of my customers to develop a "Foreign Body Reduction Plan" , based on CPMU, and to be honest, I'm at a loss

 

I had 2 complaints last year for foreign bodies in our products, my CPMU was for last year less than 0.004,  and I realise my reduction should be to get zero! but how the hell do I develop a plan?

 

Be far easier if I had loads of FB complaints!

 

Any suggestions welcome

 

Caz x

Hi Caz,

Dare I mutter RA ?   Trite yet with a touch of forboding. But maybe not for you.

Can maybe try this for inspiration although I haven't re-examined the files -

http://www.ifsqn.com...icy/#entry68504

Rgds / Charles.C

I have to agree with you Charles  - risk analysis and proactive programs are really the only route to go - and a good one at that.

Caz, if you are down to 2 complaints per year, you risk a huge percent increase if you only get one more, and I would suspect in reality it's closer to 2 +/- 2 over time.

Good opportunity to engage staff to identify possible problems and put plans in place to prevent them. The other option is to adress non-conformances and non-conforming product, but no doubt you are already doing a good job of that, and some customers may see more relevance in going the preventative action route.

John

I recommend following preliminary steps before drafting a plan.

1- Collection of data on each defect/noncompliance comprising your overall CPMU and applying QC tools over it to analyze them better. Esp, pateto will help to prioritize your focus and extent of action. While applying pareto you may adopt any of the baselines depending upon risks involved- Frequency or severity. Unfortunately some times both baselines combines. The data will guide you where to go.

2- After data analysis, do hazard assessment (as we do based on CODEX principles) based on risk involved by adopting likelihood-severity matrix.

3- Identify control measures to address each hazard or combination thereof. Extent of control measure should based on level of risk.

4- Make a format addressing type of hazard, its level, control measure, frequency of monitoring/verification and responsibility of monitoring/verification. This plan must be signed by your food safety team leader.

5- Associated with this you must have a simple check sheet to record regular monitoring/verification against your plan.

IMO, copy of all above documents and records will satisfy your customer that you are on the way of taking its feedback seriously.

Hope for the best.

Muhammad Zeeshan Zaki.

I almost feel insulted!

I'm the queen of risk assessments, and I most definitely have in place a risk assessment for foreign bodies, and how we control them etc.

I suppose I can't account for customers, as both of the FB complaints I've had in the last 12 months have been shown to be malicious contamination from the customer.

But thanks for your input, much appreciated!

Tell marketing to stop selling to assholes / the general public.  Complaint?  Well, we won't be sending you any milk.  Like that part of orange is the new black where she insults the chef and then the chef stops serving her. 

You could artificially raise the foreign body complaints in Jan by having relatives call and complain a few times, then make a corrective action you've been dying to do but haven't; had a good excuse to ("Getting a new tank will really solve our forieng body complaint issue" ).  Then once you get your shiny new hygienic stainless steel automatic CIP with no wheel print outs, have them stop calling.

I think I need a vacation XD

 

Then once you get your shiny new hygienic stainless steel automatic CIP with no wheel print outs, have them stop calling.

 

I've already got one of them! My CIP is all singing all dancing

 

Can I come on holidays with you, I'm feeling quite jaded at the moment; too many numpties in my life!