PRODUCT QUALITY & SAFETY IN

FOOD SUPPLY CHAIN - UNILEVER

 Quality in Unilever

Role of Quality
To ensure the design and production of products meet our environmental, consumer
safety and quality standards

We Manage this through …

- New product development process with clear product specifications
- UL Quality Management System
The QMS is verified annually and Quality KPIs are monitored, reported and continuously
improved on a frequent and regular basis
- A Holistic approach with Business Leaders commitment to drive the culture for Quality
excellence from all employees
 QUALITY SYSTEM ESTABLISHED IN FOOD SUPPLY CHAIN

Buying Making Delivery

Perfect
Build Quality Establish
Supplier Execution Quality in
Quality in Factories Logistic
with robust
Quality
system

We cannot optimize our performance in isolation………as part of the

overall Quality Strategy we must improve across the extended supply
chain
 1. Build Supplier Quality | Background

Any supplier can impact our

business & reputation……….so we
have to understand the
On-shelf Availability
capabilities and performance of
all of them
Consumer
Complaints &
Consumer Safety

Waste

Manufacturing
Efficiency

Excess
Inventory
BUILD SUPPLIER QUALITY | DESIGN PRINCIPLES

 Risk-based, reputable, recognized

 “Specification is King”

 Performance measurement

 Zero-defect mindset
2. PERFECT QUALITY IN EXECUTION| ROBUST QUALITY SYSTEM
FSSC 22000

• Defines the requirements of food safety management systems + all elements of

prerequisite programs + HACCP + interactive communication
Components of FSSC 22000
 Additional requirements
Part I requirements to obtain certification

• Regulatory, Statutory requirements, Code of Practices & Customer

requirements

• Specifications for services

• Supervision of personnel in application of food safety principles

• Management of Inputs: A control plan of raw materials shall be in place to

confirm product safety. The analyses shall be performed to standards
equivalent to those described in ISO 17025

• Announce, but unscheduled audits of certified organizations

2. PERFECT Q IN EXECUTION| CONTINUOUS IMPROVEMENT
4M analysis and Methods & Tools
Each quality defect we need to make a proper 4M (or 5M, 5M+E) analysis and
for each M we need to apply proper countermeasures
For each M there is a specific methodology and a specific set of tools.

4 M ANALYSIS

MACHINE METHOD MAN MATERIAL

7 Steps of Quality
7 Steps of problem solving
Maintenance

5 QUESTION TO ZERO DEFECTS

 4M Machine – 7 Steps of Quality Maintenance

3 main factors of machines quality issues

Factor 1 Factor 2 Factor 3

LACK OF BASIC CONDITIONS POOR PROCESS ROBUSTNESS MACHINE PARAMETERS ARE NOT
(MACHINE PARAMATERS NOT (MACHINE PARAMETERS ARE NOT PROPERLY SET
RESPECTED, POOR MAINTENANCE IN STABLE AND MAINTAINED DURING
AM-PM) AUTONOMY)
 4M Method – Establishment of standardized work
NOT using standardized working routines could generate:

The method must be standardized and followed correctly by the operator

If the standardized work instruction does not exist, operators carry out their jobs in their own ways,
resulting in the fluctuation of conditions, thus, change of quality. This eventually leads to reduced
yields.

11
 4M Man – Human Error (H.E.)

Human Error

Difference between the

The failure of a worker to expected result and
perform an assigned task produced result in a
correctly. process that can be
affected by human
. activity.

12
 4M Man – Human nature

Man related issues

Knowledge Lack of knowledge

Skills Overconfidence
Immaturity Education and Training

Man Bad habits due to past experiences

Attention Health problems, fatigue, worries

Excessive stress
Loose mind
Carelessness
Absent mindlessness

Misunderstanding, misjudgment, misoperation

13
 4M Man – Countermeasure against H.E.

 Human beings make mistakes however hard they are trained not to do so.

 Warning of “not to make mistakes” is relying on the unreliable human nature.

 In other words, leaving a room where people are liable to make mistakes and asking them not to
do so does not make sense

 The thinking of reducing human mistakes and the one of eliminating them are two different
things.

 The problem is the existence of a possibility of creating an error

 There is a limit for reducing human errors, we should find physical solutions to exclude human
element of making mistakes.

Make a system such that human errors cannot happen.

14
4M Material – Supplier QUALITY

For strategic
suppliers move to a
Guarantee proper supplier
incoming process control.
material Suppliers deeply
quality by involved in design
Classify and proper phase
prioritize inspection
suppliers methodology 15
 The journey to zero defects IN FACTORY
I operate equipment for
zero defects

I coach, educate
and facilitate for
I maintain equipment for
zero defects
zero defects

Operator

Quality
Professional Maintenance

I ensure that
Zero employees are
trained and
Defects systems are
followed for
zero defects
I motivate and
provide resources Supervisor
for zero defects

Factory Director
Manufacturing
Manager I focus on driving system
improvements for zero defects
3. QUALITY IN LOGISTIC | WAREHOUSE & TRANSPORT

General requirement

Warehouse requirement

Transport requirement
 Quality in logistic| General Requirement

• Quality Management system

– Management responsibility (quality & consumer safety)
– Document control
– Controls of record
– Internal audit
– Corrective & preventive action
– Management of Non conformance, Damage and Return
– Regulatory Compliance
– Incident Management
– Complaint handling
– Risk assessment & risk management…
• Key points in risk management – Pre-
requisition program:
• Storage of Food, HPC, packaging materials, Ingredients (if applicable) and
non-food chemicals must be done to prevent contamination.

• Hygienic facility must be maintained

• Access to the site must be controlled.

• A risk assessment must be conducted to identify a list of critical

equipment that impacts quality and consumer safety.

• Documented procedures must be in place for isolation and disposition of

damaged product

• Training record with defined frequency…

 Quality in logistic| WAREHOUSE REQUIREMENT
• Site security: ensures product safety and integrity
• Loading/Unloading: all incoming products must be inspected at the point of receipt
for any non-conformance.
•Design & Storage: facility and its equipment
•Traceability: must be able to trace products from supplier to customer (tested
annually)
•Quarantine & block products: must be under proper control
• Order picking: FEFO/FIFO principles
• Customer return: must monitored and recorded quality reasons
• Maintenance: facility and its equipment is maintained and minimise any risks to
product quality
• Cleaning/Personal hygiene
• Pest control
•Damages & Waste…
 Quality in logistic| Transport requirement
• Must be clean, free from odor and in a condition that enables ease of cleaning
• The container must be water tight
CONTAINER REQUIREMENTS
AREA MUSTS
Free from water surface
Floors must be dry and without condensation signs
Container Interior Clean and free from any visible contamination (previous cargos)
Free from any odor unpleasant and pleasant
Free from damage and protrusions
Hinges must be integral and free from excessive corrosion
Doors
Seals must be in a good state of repair
Closing and Locking mechanism Must be in a good state of repair ad operate

• Drivers must conform to the site rules and policy…

3. QUALITY IN LOGISTIC | CUSTOMER

• Establish quality standards hand – in – hand with customers

• Proactively listen to customers/consumer through trade-visit, product

on shelf inspection, consumers engagement center
- THANK YOU -