FOOD MANUFACTURING OPERATIONS POLICIES, PROCEDURES, AND STANDARDS MANUAL AMC-HACCP Food Safety Management System

PREFACE
Log of changes to the manual
Food HACCP definitions
References

SYSTEM AND OPERATIONS DESCRIPTION
Operation description
Products grouped by regulatory agencies
Organization and job responsibilities
Environment and facilities description
Methods for adequate grounds maintenance
Plant construction and design
Water supply
Plumbing
Sewage disposal
Toilet facilities for employees
Hand washing facilities
Waste disposal
Facility process control
Facility plan and food flow
Equipment and utensils
Major equipment items
Design, construction and use
Processes and controls
Enclosures
1.    Operation description
2.    USDA- / FDA- / FDA Fisheries-inspected products
3.    Organization chart and job responsibilities
4.    Environment surrounding the facility
5.    Facility plan and food flow
6.    Major equipment items

MANAGEMENT
AMC-HACCP Management
Food safety policy
Control of documents
Management responsibility and commitment
Food safety management plan
Evaluation of unit performance; management review
Food safety improvement program
Supervisor / Person In Charge (PIC)
Holding subordinates responsible
Product complaints
Foodborne illness complaints and hoaxes
Food security
Management
Human element – staff
Human element – public
Facility
Operations
Food sabotage
Emergencies
Recalls
Traceability
Enclosures (A)
1.    Employee-customer report of quality or hazard problem and disposition
2.    Foodborne illness information form
3.    Analysis of an alleged foodborne illness
4.    Usual incubation / onset period ranges for select foodborne disease

QA, QC, and HACCP Team
QA, QC
Control of non-conformity
Facilities, equipment, and procedures
MAP (Modified Atmosphere Packaging)
Thermometer calibration
Slush ice calibration
High-temperature calibration
Verifying refrigerator temperatures
Sanitizing solutions
Microbiological testing
New product formulation and development
Enclosures (B)
1.        Equipment / instrument calibration and verification log
2.        Refrigerator temperature log
3.        Sanitizing solution verification log
4.        Microbiological testing of production plant food items
5.        Sample identification sheet
6.        Microbiological environmental testing report
7.        Product formulation (recipe) change
8.        Product formulation (recipe) change checklist
9.        New product development project schedule
10.     New product / process development
HACCP Team
Self-inspection and food hazard control checklists
HACCP team operations
Member code of conduct
HACCP team functioning
Team membership
Team leader
Roles individuals play in groups
Some major areas for HACCP team action
Problem solving
HACCP team meeting, report, and corrective action
Filling the report
HACCP team’s measures of success
Operational improvement
HACCP reassessment
Enclosures (B)
11.     Daily QA checklist
12.     HACCP team monthly meeting report
13.     Corrective action report
14.     System capability monthly audit
15.     USDA HACCP evaluation criteria
16.     HACCP reassessment

Training Program
Training plan
Training for performance mastery
New employee training
Cross training
Continuing education and correct procedure reinforcement
Employee training records
Enclosures (C)
1.        Training plan
2.        Lesson plan form
3.        New employee training record
4.        Continuing education training record

PREREQUISITE (HACCP) PROGRAM
Personal Hygiene
Employee personal hygiene policies
Individual illness and disease control
Cuts and abrasions
Personal cleanliness
Fingernails
Hair restraint
Jewelry
Handkerchiefs and facial tissues
Chewing gum, smoking, and eating
Gloves
How to use gloves
Disposable gloves
Heavy-duty gloves
Hand washing
Employee hand washing policies
Double hand wash
Single hand wash
Medicines
First aid
Hand cuts and abrasions
Contact with blood or body fluids from another person
Enclosures (A)

Facility and Equipment Cleaning, Sanitation, and Pest Control
Substances used in cleaning and sanitizing; storage of toxic materials
Cleaning and sanitation GMPs
Pest control GMPs
Pest control program
Enclosures (B)
1.    Cleaning and sanitizing schedule and pre-operations report
2.    Sanitation procedures and standards
3.    Chemicals list and material safety data sheets
4.    Pest control schedule and report
5.    Floor plan / bait placement

Facility and Equipment Maintenance
Maintenance plan and schedule, including equipment calibration
Food contact surface equipment construction
Non-food contact surface equipment construction
Equipment operation
Gaskets
Cooling and refrigeration units
Freezers
Surplus equipment and items for repair
Dunnage racks, shelving, pallets, dollies, etc.
Backflow prevention valves for plumbing
CO2 backflow prevention valves
Warewashing equipment
Enclosures (C)
1.    Preventive maintenance schedule
2.    Maintenance procedures and standards

Supplies
Qualified suppliers
Hazard identification of food items
Ingredient specification
Defect action levels
Natural or unavoidable defects at low levels
Mixing food
Receiving and storage
Receiving
Storage
Adulteration
Aflatoxin
Contamination
Raw materials and other items
Shelf-stable products
Cold storage products
Dating and use
Single-service articles
Finished product storage
Shipping
Enclosures (D)
1.    Major suppliers of products used in the operation and their HACCP qualification
2.    Supplier letter-example
3.    Supplier hazard control of items
4.    Cook controls for safe products
5.    Supplier controls for safe products
6.    Food item allergen analysis
7.    Detailed list of food allergens and food intolerence
8.    Ingredient specifications
9.    Receiving report
10.  Receiving quality control