Wholesale

HACCP-TQM FOOD MANUFACTURING OPERATIONS MANUAL

(MODEL)


	by Hospitality Institute of Technology and Management 670 Transfer Road, Suite 21A St. Paul, Minnesota 55114 USA TEL 651 646 7077 FAX 651 646 5984 http://www.hi-tm.com Copyright 2003 March 2008 edition

TABLE OF CONTENTS
(.pdf)

(also below)

PREFACE
(.pdf)

preface table of contents only

SYSTEM AND OPERATIONS DESCRIPTION
(.pdf)

system description table of contents only

MANAGEMENT
(.pdf)

management table of contents only

PREREQUISITE (HACCP) PROGRAM
(.pdf)

prerequisites table of contents only

FOOD HACCP PROGRAM
(.pdf)

food HACCP table of contents only

APPENDIX
(.pdf)

appendix table of contents only

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

FOOD PROCESS HACCP (USDA; FDA; FDA FISH / FISHERIES)
General
    Determination if a production step is a CCP
    Quality control operations
    Methods of verification
Ingredient hazards
Chemical additives
Allergies and adverse food reactions
HACCP recipe, groups process flow charts, and HACCP plans
Physical hazards
Chemical hazards
Food manufacturing hazard and control rules
    Unprotected food items
    Physical (hard foreign) objects
    pH
    Ice
    Food tasting
    Surface heat blanching
    Food washing
    Pasteurization
    Production process control log
    Cooling
    Assembly and packaging
    Handling
    Labeling
    Finished products
    Unused food
    Use-by date
    Discards
    Water activity
    Shelf life validation
    Frozen food
    Refrigeration units
    Thawing
    Batters, breading, sauces, gravies, dressings, and other similar preparations
    Metal detection
    Food transport
    Rework
    Returned product
    Non-human food
Packaging
Enclosures
1.    Food products HACCP control groups
2.    Five USDA-based food process flows
3.   Quality-assure HACCP recipe procedures
4.   Food control group process flow charts
5.    Food HACCP plans
6.    Production schedule
7.    Production process control log
8.    Cooked product monitoring form
9.    Assemble / package production record
10.   Product specifications
11.   Product disposal record

APPENDIX
HACCP plans
HACCP recipes
Product specifications
Validation studies
Technical reports

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