hide & seek - food focus · • cadbury uk 2006 • salmonella montevideo in milk chocolate •...

Hide & SeekFinding Pathogens through

Inspection

Rolf Uys, Entecom

Where’s the Panda?

Intro

2 Audits vs Inspections

3 Inspection structure

1 Fix the basics

4 Where to look?

BackgroundIntro

5 Virtual Audit

2

BackgroundFix the basics 1 2 3 4 5

• Cadbury UK 2006

• Salmonella Montevideo in Milk chocolate

• Cost:

• 1 million bars, 7 lines

• + Recall costs + medical bills + lost revenue

• Excluding future sales loss, fines

Total cost = R 260 000 000

2

BackgroundFix the basics 1 2 3 4 5

Processed meats

2

BackgroundFix the basics 1 2 3 4 5

If we have dead rats, we probably have Listeria also

2

BackgroundFix the basics 1 2 3 4 5

The mother ship in the Alien movie ?

2

BackgroundFix the basics 1 2 3 4 5

Ablutions

2

BackgroundFix the basics 1 2 3 4 5

Good Storage practices ?

2

BackgroundFix the basics 1 2 3 4 5

2

BackgroundFix the basics 1 2 3 4 5

Bin usage ?

• False sense of security

• Too little actual time spent in the plant

• Lack of auditor technical expertise

We have a certificate, we can’t have Pathogens

Audits vs Inspection 1 2 3 4 5

PASSING A FOOD SAFETY AUDIT

Audits vs Inspection 1 2 3 4 5

1. Fill in a few checklists

✓

✓

✓

✓

✓

✓

✓

✓

✓

5. Get the certificate

2. Appoint a bad ass Quality Manager 4. Do the big clean-up

3. And a good document controller

Audits vs Inspection 1 2 3 4 5

ISO 19011

Audits vs Inspection 1 2 3 4 5

Audit• Evaluation of policies,

procedures, (systems)• Historical records over time

Inspection• Physical, on the floor

assessment• Moment in time

Audits vs Inspection 1 2 3 4 5

• Inspection structure:✓ Taken seriously by the top

..and the bottom✓ Who’s in the Team?

Inspection Structure 1 2 3 4 5

• Follow up:✓ Proper Root cause Analysis✓ Track and hold accountable

Inspection Tools

Inspection Structure 1 2 3 4 5

Inspection Structure 1 2 3 4 5

Next level:

Where do we start? ✓ Perimeter, then line by line✓ Observe, Interview, Challenge✓ Chase down the smoking gun✓ Try to cover production, non-

production, cleaning & maintenance

Where to look? 1 2 3 4 5

Think like a lazy cleaner

Where to look? 1 2 3 4 5

Where to look? 1 2 3 4 5

Pictures: How to inspect

Virtual audit 1 2 3 4 5

Virtual audit 1 2 3 4 5

Virtual audit 1 2 3 4 5

Where to look? 1 2 3 4 5Virtual audit 1 2 3 4 5

Virtual audit 1 2 3 4 5

BackgroundSummary

BackgroundSummary

Where’s the Pandanow?

Quality Manager

BackgroundSummary

Up for a pathogen inspection?

Need training: Contact rolf@entecom.co.zaNext course: Basic Micro/EMP : 27 August

rolf@entecom.co.za

www.entecom.co.za

@rolfuys