HOW TO PASS A FOOD PLANT AUDIT

BRILLIANTLY

19 October, 2016

Ms. Cheng Ai Ling

Client Development
Manager ,
Asia Pacific & China

Ai Lings History
18 years experience in the food industry.
8 years with AIB International
Previously with Meat Processing and
Animal Feed Local companies
Quality Background

AS1

AIB International
Non-profit membership
organization
800+ members
Headquartered in Manhattan, KS
Offices in:
Surrey, UK
Mexico
Shanghai, China
Over 300 full-time professionals
29% International
Employees based in 26
countries, serving customers in
124 countries

Slide 4
AS1

Since when AIB shift into profit organization?

Arsi Subandoro, 7/5/2015

AIB International
Global Company Conducting
Business in 124 Countries

SOFHT JAN 2016

AIB International
We touch many points in the food & beverage
supply chain

Ingredients
and
Package
Processor

Transportation
and
Storage

Food

Retail

and

and

Beverage

Food Service
Outlet

Manufacturer

Consumer

AIB International
Value Added
Dairy
Ready to Eat
6%
6%

Grain-Based
Warehouse

Ingredients
6%

Grain-Based
32%

Beverage
11%
Packaging
15%

Packaging
Beverage
Ingredients
Ready to Eat

Warehouse
24%

Value Added Dairy

Professional Service Company Supporting Food & Beverage Industry

INSPECTION & AUDIT PROCESS

Independent,
Independent, BUT working together
Inspection
Inspection

Audit

Audit

Inspection

Audit

AUDITS
A systematic evaluation to determine if programs and
related activities achieve planned expectations
Reviewing / challenging:
o Written programs
o Documentation of activities records
record
o Corrective actions
o Trends
Helps determine correlation between documented
procedures / activities and actual execution
Can assist in identifying root cause and can lead to long
term corrective action

INSPECTIONS
An assessment of a moment
moment in time
time which identifies
o Positive or negative conditions
An extensive
o physical inspection of the facility/ equipment
o observation of practices
to collect information in order to determine compliance
with plant programs
Initiates immediate corrective action if needed
Often leads to an evaluation of programs and systems

KNOW WHICH AUDIT & INSPECTION CRITERIA

Food Safety Audits

ISO 22000
BRC
FSSC 22000
SQF
HACCP
IFS
Retail e.g. Tesco, Walmart, etc.
Customer specific e.g. Nestle, McDonalds, etc.

Food Safety Inspections

AIB GMPs
Food, beverage, food contact packaging,
distribution center, etc

KNOW WHICH AUDIT & INSPECTION CRITERIA

Version
Use correct standard and current version
Be aware of any pending updates/revision.

TRAINING & EDUCATION

What needs to be done?
Why does it have to be done?

TRAINING & EDUCATION

Standard
GFSI Standards
HACCP
Food Defense/Security
Legislations
Country of sale
Manufacturing country

TRAINING & EDUCATION

Relevant programs (external)
IPM
Allergen
Sanitation
Hygiene Practices
Sanitary Design
Environmental testing
Etc.

TRAINING & EDUCATION

New or revised SOP, policy,
procedures, WI, records
Use of photos, videos, demos
Verification and supervision to
ensure compliance

GAP ASSESSMENT
Standard requirements
Current documents
Physical Inspection

GAP ASSESSMENT

Standard
Scoring
Critical/Major/Minor/Observations
Unsatisfactory/Serious/Improvement
Needed/Minor
Identify
Automatic Unsatisfactory Issues

GAP ASSESSMENT
Current Document
Procedures
WI,
Records
Policies

GAP ASSESSMENT
Physical Inspection - Internally
Inspection Tools
Notes
Safety equipment (optional)
Communication skills

PHYSICAL INSPECTION
Establish team
Food Safety Committee/Food
Safety
Multi-disciplinary
Key personnel e.g.
Leader/FSTL/Coordinator

INSPECTION TOOLS

RISK
HIGH
M
E
D
I
U
M

HIGH

Low

M
E
D
I
U
M

TERMS AND DEFINITIONS

Direct Contact Surfaces:
Shall mean all surfaces which are exposed to the
product or from which liquids may drain, drop,
diffuse or be drawn into the product
Indirect Contact Surfaces:
adjacent to direct contact surfaces
Non-product Contact Surfaces:
Should mean all other exposed surfaces

DIRECT CONTACT SURFACE

Indirect contact surface

Train yourself to see what

others overlook.

Looks good from this side.

Secured side

Commons findings
and
best practices

By AIB

Ready?

TAKE GOOD NOTES

PHYSICAL INSPECTION
Schedule / Plan
What is needed
Hard issues e.g. equipment,
structures, repairs, upgrading, etc.
Manpower
Documentation

GAP ASSESSMENT
Gap Assessment by 3rd party at initial
stage
Consultant
Trainer
Pre-assessment audits by 3rd party
Support from corporate or sister
companies

SELF-INSPECTIONS & INTERNAL AUDITS

Corrections done?
Trend results when few sessions have been
completed together with customer complaints and
other internal non-conformances
Review recurring issues
Troubleshoot on root cause
ICE
5 Whys
Fishbone diagram
Etc.
Long term corrective actions to prevent recurrence

AUDIT / INSPECTION PREPARATIONS

Announced or Unannounced (ready all the time)
Secure audit plan ahead of time or request during
Opening Meeting
Have key people to answer auditor (including backup) and acceptance of findings
Prepare documents ahead of time
Have a room or area for auditor to work

AUDIT / INSPECTION PREPARATIONS

Caution on last minute preparations for announced
audits:
Wet or strong paint odor impacting products
Leaving cleaning water behind on equipment e.g.
metal detector causing inconsistent function
Overhead cleaning without covering or taking care of
below areas causing debris on unintended equipment
or structures.
Improper use of domestic pesticide

ACTUAL AUDIT / INSPECTION

Actual day
On time Opening and Closing meetings
Reconfirm audit scope (if the entire site is not audited)
Highlight any changes different to audit plan
Provide any required documents to auditor before
physical inspection:
Pest schematics
Flow diagram
HACCP/OPRP master plan
Be ready with tools to open up cabinets, equipment or
ladder, etc, required.
Personnel ready for any disassembly of required
equipment.

ACTUAL AUDIT / INSPECTION

Tips
Key personnel answering accurately as info is used for
rating.
Avoid delays in confirming info
Requested documents ready promptly
Cooperate with auditor without pressure to meet
company/corporate KPI
Have backback-ups in case you need to be away to find
documents or people.
OnOn-time lunches and breaks
Immediate corrections for issues found
Per company procedure
Prevent risk to the product

ACTUAL AUDIT / INSPECTION

Stick with facts. Answer the questions directly instead of
providing long and irrelevant answers in stall tactics or
prevent score reduction.
Be transparent, honest and gain auditor trust

KEY TO SUCCESS

Top Management Commitment

Team Work
Buy-in from everyone
Training and education
Goal setting & monitoring (SMART goals)
Practice, live the standards and company requirements
(culture)

BE PREPARED AND
THANKS FOR
YOUR ATTENTION