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The GBC Food Safety and Quality Requirements Matrix ISO 22000:2005

Clause 1.1 1.1.1 1.1.2 1.1.3 1.1.4 1.1.5 1.1.6 1.1.7 1.1.8 1.1.9 1.1.10

Issue Top Management

Requirement

Documentation Required

Evidence

Policy, signed and communicated Objectives Senior management review Managmeent meeting program Provision of resources Industry updates Copy of the standard Maintain certification Attendance at opening and closing audit meetings Root cause analysis of past nonconformances

x x x x

Policy Objectives and attainment plan Review meeting minutes Monthly meeting minutes Conferences, memberships, technical journals, e-mail updates Copy of the standard or receipt

Review of non-conformances, root cause analysis, verification

1.2 1.2.1 1.2.2 2 2.1 2.1.1

Organizational structure and authority Organizational chart and absence coverage Job descriptions and work instructions HACCP HACCP team HACCP team, training
Team list and training records

x x

Organizational chart, deputies, list of responsibilities

Job descriptions and work instructions

2.2

Prerequisite programs

2.2.1 2.3 2.3.1 2.3.2 2.4 Intended use Product description

Prerequisite programs

Scope of HACCP plan, products and process descriptions Source of product / process description

x x

2.4.1 2.5 2.5.1 Verification of flow diagram Flow diagram

Description of intended use, specific risk target groups, potenital misuse of product

Diagrams illustrating process flow and layout schematic

2.6 2.6.1 2.7 2.7.1 2.7.2 2.7.3 2.8 2.8.1 2.9 2.9.1 2.9.2

Flow diagrams verified and challenged annually Listing of hazards Listing of potential hazards Definition of hazards hazard control measures CCP determination Using decision tree, identify which control points are CCP's CCP limits Limits for each CCP defined Validation of CCP's

x x x

decision tree

x x
validation studies showing that control measures and limits will effectiveyly control hazards in all forseeable circumstances

2.10

CCP monitoring Procedures for monitoring CCP limits, and corrective actions in case of limits being exceeded Recording of monitoring Corrective action Procedures to follow in the event of limits being exceded as well as failure of control measures Verification Activities to ensure the HACCP plan is effective

2.10.1 2.10.2 2.11

P P
Recording and verification procedures (verification to include verifying records as well as actions)

2.11.1 2.12 2.12.1

2.13 2.13.1 2.14

HACCP documentation and record keeping Records created and maintained to verify HACCP is actively in place HACCP review Review of both implementation and effetiveness of the HACCP plan verified annually or in the event of significant changes x

2.14.1

3 3.1 3.1.1

Food safety and quality management systems Food safety and quality manuals All policies and procedures are documented.

3.1.2

3.1.3 3.2 Document control

Fully implemented and available where needed Policies, procedures and work isntructions are formatted as to be understandable to staff

3.2.1 3.3 3.3.1 3.3.2 3.4 3.4.1 3.4.2 Internal audit Records

Mechanism for controlling document versions, change log and update procedure

list of controlled documents, change log, change procedure

Records are understandble, record alteration procedure Record retention procedure

P P

reasons for alteration of records is documented on record

Internal audits cover all requirements of the Standard Internal auditors appropriately trained Internal audit reports show evidence of conformance, and closure of nonconformance Internal inspections covering site conditions and hygiene 3.5 Supplier approval and monitoring Raw materials and packaging Listing of all ingredients and packaging, and associated risks Supplier approval procedure, and ongoing monitoring procedure Exception procedure in case of nonapproved supplies being used

Internal audit report

audit technique training for internal auditors

3.4.3 3.4.4

x x

internal audit report

inspection reports

3.5.1 3.5.1.1 3.5.1.2 3.5.1.3

x P P

grouped or individual listing of all materials

3.5.2

Acceptance monitoring Procedure on how incoming materials are assessed for acceptance Records of acceptance Service supplier management Procedure for approval and monitoring of service suppliers Service contracts adressing specifications or expectations P x
contracts and specifications for service suppliers reveiving inspections, pre-use testing, additional document requirements Proof of acceptance

3.5.2.1 3.5.2.2

P x

3.5.3 3.5.3.1 3.5.3.2

3.5.4 3.5.4.1 3.5.4.2 3.5.4.3 3.5.4.4 3.6 3.6.1

outsourced processing management Brand owner is aware of outsourced processing Monitoring of contracted processing Managing of contracted processing Monitoring of contract processing results Specifications Specifications in place for all raw materials and packaging Activities and instructions on the process floor equate to product and customer specifications Specifications in place for all finished products Specifications are agreed with or available to customers x
specifications

x x x P

docmented in contract with brand owner verification of certification or audit reports contracts of specification and expectation in place

results and analysis of process outcome

3.6.2 3.6.3 3.6.4

specifications

3.6.5 3.7 3.7.1 Control of nonconforming product Corrective action

Specifications are reviewed when required, minimum every 3 years

Documented procedure for corrective actions

3.8 3.8.1 3.9 3.9.1 3.9.2 3.9.3 3.10 3.10.1 3.10.2 3.11

Hold program, including dispensation program Traceability Identification of all materials within site to allow traceability Mass balace and traceability test Rework is included in traceability program Complaint handling Complaint program, resolved through trained staff Complaint data analyzed for trends and used for improivements Incident management Incident management procedures based on potential large scale interruptions Recall and product withdrawal procedure Procedures tested annually Notification of CB in the event of recall Site Standards

test results

ongoing trend analysis for complaint data

3.11.1 3.11.2 3.11.3 3.11.4 4

P P

CB on recall contact list

4.1 4.1.1 4.1.2 4.1.3 4.2

External standards Protecting site from external contaminants and impacts Site exterior maintained in good order Building exterior maintained in good condition Security Security risk assessment and mitigation completed, reviewed annually Controlled access and employee security training Registered with appropriate government agencies, where required Layout, flow and segregation Site map designating product risk zones Site map identifying activites Visitors and contractors managed on site Contamination control in low risk areas High care areas provide appropriate practices High risk areas segregated, and use appropriate practices Sufficient space to work effecitvely hygenically Temporary structures do not add risk Building
site map, appropriate zone designations

4.2.1 4.2.2

4.2.3

Proof of registration

4.3 4.3.1 4.3.2 4.3.3 4.3.4 4.3.5 4.3.6 4.3.7 4.3.8 4.4

site map

sign in and awareness activities

4.4.1 4.4.2

4.4.3

4.4.4

Walls constructed and maintained to appropriate standard Floors constructed and maintained to appropriate standard Drains constructed and maintained to appropriate standard. Drainage does not impact product integrity If HC /HR, then msut have a drain plan showing drains, flow direction, back flow prevention or other risks. Ceilings and overheads construted and maintained to appropriate standard Suspended ceilings (building voids) on inspection program Ventilation to outside is pest proof. Windows protected from breakage where they pose a risk Doors constructed and maintained to appropriate standard. Doors do not allow pest ingress. Lighting is suitable and sufficient Light bulbs protected from breakage Adequate ventilation and extraction HR areas using filtered air. Utilities Water is potable, plant tested for relevant contaminants. Water distribution plan Restrictions if non-potable water is used. Steam, compressed air, gasses, do not pose contamination risks. Compressed air with direct product contact is filtered. R x

Drain plan / drawing

4.4.5 4.4.6 4.4.7 4.4.8

Void inspection record

4.4.9 4.4.10 4.4.11 4.4.12 4.4.13 4.5 4.5.1 4.5.2 4.5.3

Plant sample test results. plan showing all taps, outlets and storage.

If used, reference to legislation.

4.5.4

HACCP process flow diagram showing use of utilities, verify protection.

4.6

Equipment Equipment designed, constructed and installed to be effectively cleaned and maintained. Equipment with direct food contact made of suitable materials. Maintenance Preventative maintenance program is effective Equipment inspection program where not covered by PM program Temporary repairs controlled Product protected during maintenance activities. Post maintenance line clearance procedure used. Approved chemicals / materials used in maintenance. Shop and engineering rooms maintained Staff facilities Adequate changing facilities for employees and visitors Personal storage for employees. Separate storage for clean uniforms provided. In HC areas: - segragated changerooms, changing instructions, footwear dedicated to high care area only, distinctive clothing, handwashing during changing, handwash and sanitize on entry x
PM program

4.6.1 4.6.2 4.7 4.7.1 4.7.2 4.7.3

Approvals of suitability or conformance

Inspection program Work orders tied to temporary repairs

4.7.4 4.7.5 4.7.6 4.8 4.8.1 4.8.2 4.8.3

P
Approvals for materials based on use

4.8.4

4.8.5

4.8.6 4.8.7 4.8.8

4.8.9

4.8.10

In HR areas: - changing instructions, dedicated footwear, footwear barrier system, disctinctive clothing, handwashing during changing, hand wash and sanitize on entry Handwashing to include: - suitable temperature, liquid soap, single use drying, hands free taps, signage Washrooms: - segragated, handwashing with signange Smoking and waste managed to protect product Employee food stored in clean hygienic state. No food in production or storage areas. Cafetria operations suitably controlled to prevent contamination and employee illness

cafeteria training, inspections

4.9 4.9.1

Chemical and physical contamination control Chemical controls Approved purchase, specifications, suitability proof, avoidance of scented products, appropriate labeling, segregated and secure storage, use by trained personnel protect product from chemical taint Metal control Sharps and knife control procedures Protection from staples, paper clips, and other closures Glass and brittle material control Excluded or protected p
sharps policy

4.9.1.1 4.9.1.2 4.9.2 4.9.2.1 4.9.2.2 4.9.3 4.9.3.1

4.9.3.2

List of items, location and condition. Periodic check program, procedures for cleaning and replacing as needed. Glass breakage procedure: - quarantine, cleaning, inspection and authorization, clothing change, training and recording Products packed in glass Segragated storage of empty containers Breakage control: - removal of product, cleaning, designated cleaning materials, lidded waste containers, post breakage inspection, restart authorization records of breakage Wood Restricted use, monitoring of condition

4.9.3.3 4.9.3.4 4.9.3.4.1

4.9.3.4.2 4.9.3.4.3 4.9.4 4.9.4.1

4.10

Foreign body detection and removal equipment Foreign body detection and removal equipment Risk assessment to assess need choice and installation based on industry best practice System testing frequency risk based Investigation and trend analysis of findings Filters and sieves

4.10.1 4.10.1.1 4.10.1.2 4.10.1.3 4.10.1.4 4.10.2

findings report / investigations /trend analysis

4.10.2.1 4.10.2.2 4.10.3 4.10.3.1 4.10.3.2 4.10.3.3 4.10.3.4 Metal detectors and xray

Investigation and trend analysis of findings inspected and checks recorded

Risk assessment to assess need. Justification for absence choice and installation based on industry best practice Reject or stop and alarm system Operating and testing procedures. checks to include: - labelled test pieces, ferrous stainless and non-ferrous, detect and reject tested, memory / reset tests, use of sample test packs Test failure procedure Magnets Magnet specification, inspection, cleaning and testing Optical sorting Operating and testing procedures. Container cleaning cleaning and protection of containers based on best practice Cleaning effectiveness tests. Housekeeping and hygiene SSOP's Defined expectations for cleaning Time and resources for effective cleaning Cleaning verification Dedicated, distinctive cleaning equipment properly managed

4.10.3.5 4.10.3.6 4.10.4 4.10.4.1 4.10.5 4.10.5.1 4.10.6 4.10.6.1 4.10.6.2

p p

p p

4.11 4.11.1 4.11.2 4.11.3 4.11.4 4.11.5

4.11.6 4.11.6.1 4.11.6.2 4.11.6.3 4.12 4.12.1 4.12.2 4.12.3

CIP Systems monitored and maintained Appropriate desgin and installation, system change log maintained Monitored system conditions, effectiveness testing Waste Licences of waste contractors, including those for recycling Food waste and animal feed streams segragated External waste collection identified and maintained Unsafe or trademarked materials appropriately denatured and destroyed Pest control Competent persons perform risk assessment and manage pest control If company managed pest control, effective competency and systems in place Adequate pest control documentation and records Outdoor baits secured in place, no rodenticides indoors Bug lights appropriately locted and functional Approprate actions in the event of infestation Inspection records and follow up of recommendations Additional effectiveness survey, typically quarterly
contract, training or licencing

x P

schematic

contracts / licences

4.12.4 4.13 4.13.1

licence, record of destruction

4.13.2 4.13.3 4.13.4 4.13.5 4.13.6 4.13.7 4.13.8

licencing, training records, chemical controls

site map, product specifications, pest control reports

pest inspection records

effectiveness report

4.13.9 4.14 Storage facilities

Trend analysis of inspections and catch records minimum annually

trend analysis

4.14.1

Procedures adequate to ensure product integrity during storage are in place, understood and followed Where temperature control is required, it is sufficient and monitored Where controlled atmosphere is required, it is maintained and records maintained Stock rotation systems are effectively in place during storage Shipping and transportation Product integrity is maintained during loading Traceability is maintained during shipping Pre-load inspections performed and recorded Where temperature control is required, it is documented Unloading equipment maintained and clean Transport procedures to ensure product integrity, including security and breakdown Sub-contracted transportation meets all requirements of section 4.15 Product control

4.14.2

temperature monitoring

4.14.3 4.14.5

4.15 4.15.1 4.15.2 4.15.3 4.15.4 4.15.5

P
shipping records indicate lots

inspection records

temperature monitoring records

4.15.6 4.15.7 5

P
contract, load sign off documents

5.1 5.1.1 5.1.2 5.1.3 5.1.4 5.1.5 5.1.6

Design and development Guidelines and restrictions on R&D introducing new hazards HACCP review completed prior to product introduction to operations Product trials where needed to validate process Shelf life trails or data completed Label design satisfies requirements and regulations of country of sale Lable claims have validated evidence
R&D review policy

target market label regulations and approval process

5.2

Allergen management Risk assessment as to potential for raw materials to be contaminated with allergens List showing all allergens on site Risk assessment to identify vectors of allergen contamination Documented allergen segragation procedures in place and effective If rework of allergen containing materials is carried out, appropriate controls in place If contamination connot be effectively controlled, appropriate consumer lable warnings in place Validation of allergen free label claims Allergen cleaning procedures validated and verified. Allergen cleaning equipment segragated and identified

5.2.1 5.2.2 5.2.3 5.2.4

supplier certification or questionaires

what and where allergens are found

5.2.5

5.2.6 5.2.7

validation studies

5.2.8

cleaning validation studiues

5.2.9 5.2.10 Provenance and assured status

All persons entering the site shall have allergen awareness training Effective packaging changeover system

visitor and contractor training

5.3 5.3.1

Where provenence is required, raw material verification in place Records of material provenance maintained. Mass balance every 6 months Process flow specific to assured status products documented and appropriate controls to maintain in place Product packaging Documented evidence of suitability based on intended use for all packaging Storage conditions suitable to maintain packaging integrity. Obsolete packaging suitably controlled Product contact liners for work in process and ingredients purchased by the company appropriately colored

certificates for raw materials

5.3.2

mass balance results

5.3.3 5.4

flow diagram specific to assured status product

5.4.1

proof of material compatability

5.4.2

5.4.3

5.5 5.5.1 5.5.1.1

Inspection and testing Product inspection and testing Product testing program based on risk

5.5.1.2 5.5.1.3 5.5.2 5.5.2.1 5.5.2.2 Lab testing

Results reviewed, analyzed, and where needed, acted upon Ongoing shelf life studies in place

trend analysis

Pathogen testing fully segragated Laboratory controls in place to prevent contamination Critical lab testing performed by accredted laborotory, or in accordance to accredtation guidelines Good lab practices in place Product release Where required, positive release procedures fully implemented Process controls Control of operations Process specifications and work instructions available and suitable Process monitoring in place to esnure production meets specifications If process controls are automated, suitable tested failure alert system is in place Process validation frequency basd on risk Procedures to evaluate product in the event of process deviation Product changeover procedure Product packaging verification Quantity control
process validation matrrix

5.5.2.3 5.5.2.4 5.6 5.6.1 6 6.1 6.1.1

lab accreditation

6.1.2

6.1.3 6.1.4 6.1.5 6.1.6 6.1.7 6.2

P P P

changeover pre-op inspections packaging verification checks

6.2.1 6.2.2 6.3 Calibration

Weight control programs meet regulatory requirements Weight control programs meet customer specifications

regulation for country of destination

6.3.1 6.3.2 6.3.3

6.3.4 7 7.1 7.1.1 7.1.2 7.1.3 7.1.4 7.1.5 7.2 7.2.1 7.2.2 Personal hygiene Personnel Training

Equipment to be calibrated is: documented, identified, scheduled, protected Calibration frequency based on risk and procedures based on standard Reference calibration equipment traceable to Standard Procedures to follow in the event of equipment found out of calibration and product potentially at risk

calbration methods and matrix

calbration certificate of standards

Pre-employment training for staff, temps and contractors Training relevant to CCP`s Assessment and delivery plan for staff training Records of training Staff competency and training effectiveness assessments

job / training matrix

P Policies for jewelry, nail care and personal hygiene Hand cleaning on entry to production areas Cuts protected, bandages appropriately colored, meteal detectable.

jewelry policy

7.2.3

7.2.4 7.2.5 7.3 Medical screening

If metal detectors are present, bandages are tested for detection Personal medicine policy and procedure

x P

test results

7.3.1 7.3.2

Procedure for employees to notify site of sickness or sympton if relevant Notification to visitors of health and sickness risk and procedures Procedure for site to follow if employees or visitors indicate they may be suffering from a relevant disease Protective clothing Protctive clothing policy, including wearing outside of the work environment Protective clothing is suitable to protect the product Work wear laundered by service contractor or in house. Self laundry only for enclosed or low risk zones Laundry for HC / HR areas includes: laundry procedures, commercial sterilization, segragation, protection of clean work wear Gloves suitable for purpose, preferably colored. Non-launderable articles maintained clean and sanitary.

P P

7.3.3 7.4

7.4.1 7.4.2

7.4.3

7.4.4 7.4.5 7.4.6

High care / high risk

SM SMR KPI FSQA NC Standard Key staff key information SLQ FS

Senior management senior management review - the meeting key performance indicators - measures food safety and quality assurance - functional level non-conformances refer to specific clause in the standard, no explanation required persons with responsibility for product safety, legality, regulatory compliance and quality systems Information with regard to safety, legality, regulatory compliance and quality systems safety, legality, quality - the focus of the BRC program food safety

Positive comment for auditor Opportunity for improvement for auditor Minor non-conformance Major non-conformance

Key requirements:

Senior managmeent ownership and support Document control system Training control system Risk assessment and management Making safe product meeting customer specivications (saving customers) Due diligence (saving job and company) An efficient and value added audit (saving money and time)

Goals to work toward:

mpliance and quality systems d quality systems

Clause

Event

Expectation

Evidence

Outcome Issues identified, action plans in place, resources allocated, targets defined, verification of results

1.1.3

Senior management review

Meeting to ensure food safety and quality measures are in place and appropriate action plans managed Meeting minutes

1.1.4

Management meetings

Program of meetings to track objectives, issues and ongoing operational results Ensure flow diagrams used within the HACCP plan and other areas are up to date and accurate

Meeting minutes Singed and dated flow diagrams, or other evidance of their verification

Periodic review of objectives and operational performance, a means of steering the operation to ensure overall goals are met and maintained. Data analysis for senior management review. Flow diagrams support control activities, reported in internal audit

2.6.1

Verification of HACCP flow diagrams

2.14.1

HACCP review

Comprehensive review of the HACCP plan, to ensure it is effectively in place and adequately manages risk within the operation Review notes All clauses and requirements of the stadnard are audited to ensure effective compliance

HACCP plan accurately reflects the process. Reported to senior management review

3.4.1

Internal audit

Documented evidence showing conformance to the standard. Reproted to senior Internal audit report management review Site conditions and activities meet expectations. Reported to monthly management meetings

3.4.4

Internal inspections

Environmental and hygiene programs and results audited and inspected

Inspection report

3.6.5

Specifications

Specifications are periodically reviewed to ensure accuracy to current operations

Specification review Site ensures program or dated specifications are up to specifications date.

3.9.2

3.11.3 4.2.1

Mass balance of finished goods, raw materials and Traceability test packaging tested Recall procedure is validated and tested to ensure operational readiness and Recall test effectiveness Security risk Operation security risks assessment assessed

Test results

Full traceability achieved within 4 hours

Test report Security risk assessment report

Opportunity for process improvements Opportunity for improvements

Minimum frequency

Annual

Monthly

Annual, or in the event of changes

Annual, or in the event of changes

Annual, or more frequent based on risk

Monthly

Every 3 years or more as required

Annual

Annual Annual

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