managing your supply chain for food safety in a global environment dane bernard keystone foods

Managing Your Supply Managing Your Supply Chain for Food Safety in Chain for Food Safety in

a Global Environmenta Global Environment

Dane Bernard

Keystone Foods

BackgroundBackground

Food companies must rely on multiple companies and Countries for food ingredients and packaging.

Items can be manufactured in all parts of the world. “Expectations” placed upon suppliers is the

foundation for food safety and quality. tartartrace.xls

Expectation AreasExpectation Areas Animal Welfare (if applicable) Biosecurity/Food Defense BSE Firewalls (if applicable) Residue Control Sanitation Pest Control Good Manufacturing Practices / Good Agricultural Practices

Practices HACCP Foreign Material Control

Expectation AreasExpectation Areas

Product Withdrawal Hold Procedures Product Storage Load Security Lot Identification Lot Control Traceability Laboratory Support (if applicable) Laboratory Testing Capabilities (if applicable).

Animal WelfareAnimal Welfare Requirements specific for each species

Safe and responsible animal treatments

Accountability Auditable to acceptable standards Verified by all levels

Internal audits Second and third party audits

Corrective actions Increasing use of Video Monitoring

SanitationSanitation

Written Sanitation Standard Operating Procedures (SSOP’s)

Clearly defined responsibilities Assessment of effectiveness

Preoperational visual inspection Equipment swabbing with tracking and trending Corrective action plans

Use of appropriate sanitary design

Foreign Material ControlForeign Material Control A systematic approach that considers sources of FM

from: People Place Product

Prefer: active “audits” Risk Ranking [Using Failure Mode Effects Analysis

framework] to prioritize Tracking and follow through

Eliminating a High Risk RPNEliminating a High Risk RPN

This Batching combo hoist has Nylon guards which contaminate product due to the scraping of metal combos against the Nylon. These are not required as all suppliers use cardboard combo’s

RPN 0RPN 140

Thermometer ControlThermometer Control

In the facility there are many thermometers used and constantly make contact with product. These thermometer holding areas have been installed in areas where they are used.

“If the thermometer is not in its designated location, it is in use”

RPN 432 RPN 120

Load SecurityLoad Security

Keystone policy is that all loads must arrive with acceptable seal applied at departure point or trackable history of seal that is in place upon arrival.

Cable or bolt seals are required on all access doors For less than truck load shipments, security must be

applied at case and or pallet level.

TraceabilityTraceability

One up, one down is the minimum expectation Questions remain about extent of uniformity that will

be needed on product and ingredient coding systems to be able to be more proactive on addressing food safety issues.

Approval ProcessApproval Process

Basic understanding of the supplier’s capabilities. Outlining our expectations. First or Third party assessment of conformance to

expectations. Poultrysupplieraudit.docx “Probationary” approval.

Limited purchases until a baseline can be established linking supplier performance with conformance.

Active purchasing. Name placed on the Approved Supplier List (ASL).

Approved Supply List Approved Supply List (ASL)(ASL)

Specific locations which a Keystone facility can purchase items.

Contains the “latest history” of a supplier. Annual audit results. Contact information. Non conformance results.

Names of plants which have been delisted. ASL is a living document and should always be

current.

Supplier VerificationSupplier Verification Prioritize suppliers Pre-ASL audit compliance. Initial load(s) testing (if applicable). Normal monitoring schemes in place.

Product dependent• Time• Type of monitoring

Annual Audit Third Party Audit Keystone Audit

Meeting ExpectationsMeeting Expectations

Non Conformance expectations must be established. Differing levels of actions

• Minor infractions – corrective actions• Major infractions – corrective actions and possible follow up• Critical infractions – suspension of supply

Trending of data may indicate suspension of supply without a critical defect failure.

• Micro trends?• Foreign material trends?

CommunicationCommunication

Constant feedback is a MUST! [by Whom?] Helps keep your expectations up to date. The goal is to have confidence and consistency in

the products you receive. One Tip – Partner with purchasing! Conduct frequent

program reviews.

SummarySummary

Be selective; look for value not just price Clear expectations then verify Maintain and enhance the program

Keep it simple: • Start with risk ranked suppliers and limited scope of

expectations• Elaborate on expectations• Verify conformance with audits and appropriate

testing/observations

I’d rather be here than shoveling snow in US!

SummarySummary