美国亨氏食品验厂标准hein.doc

Issued by : Paul McLoughlinAuthor C Harris Reference : EM023.06 Date Issued : 05 Feb 2004. H.J.Heinz Vendor QuestionnairePart 1SUPPLIER / MANUFACTURER SPECIFIC INFORMATIONName of Company: _ Foods Co.,Ltd. Address: _No._Shandong Province,China _Telephone Number: _+86-5- _Fax Number: _+86-5 _Address of Production Site(if different from that given above) Contact Personnel and Title: _Trading manager_Principle Production/Process: _Frozen vegetables and fruits_Other Production/Process: _ _Material to be supplied to Heinz: _Frozen asparagus,strawberry,onion dices,pepper slices/dices,yellow peach dices,spinach,broccoli,white cauliflower,garlic dices/cloves,etc. Total No. of Production Personnel: _400_Total No. of Inspection Personnel: _10_Date of construction of premises: _June,2000_Approximate area of site: _26,600 square meters_Completed by:(Signature and print name)_Position: _Trading manager_ Date completed: _March 05,2005_Supporting Information If any part of the process (including storage or laboratory services) is contracted out or undertaken at a different site, please provide details. Please provide a Management Organisational Chart for the manufacturing site. Job titles only are necessary. If the site has a documented quality control system that has been approved to ISO 9000 or equivalent, please provide details of accrediting body, accreditation number and scope of accreditation. IndexPlease complete and return the sections indicated below, providing as much supporting evidence as possible. Section Title Return Required Section 1. Food Safety and Quality Systems . Yes Section 2. Ethical Trading .YesSection 1 Food Safety and Quality Systems.1.0 PEST CONTROLGUIDELINES / EVIDENCECOMMENTS1.1A documented pest control programme has been established.A documented pest control programme, which includes: a designated pest control operator (PCO) scheduled service intervals pesticides used and location of useTrap placement and location mapA formalized pest control program was established with written procedures outlining the requirements of the program to reduce the potential for product contamination from pest activity or use of materials and/or procedures designed to control pest activity. the individuals responsible for pest control in the facility receive formalized general pest control training, as well as specific training for insecticide applications.2.0 CLEANINGGUIDELINES /EVIDENCE COMMENTS2.1Equipment and facilities are visually inspected after cleaning by an independent operator. Effective cleaning practices are evident. Visual Evidence Documented inspections Corrective actions completed Preventive actions put in place. Detailed, written cleaning procedures were developed and on file for all cleaning tasks in the facility. These procedures included the chemicals, concentrations, tools, and disassembly instructions for equipment at the level needed to facilitate the appropriate sanitation maintenance of the processing and packaging equipment, building areas, and outside grounds.2.2Cleaning procedures are documented and cleaning is effectively scheduled.There should be a master document in place, which includes: cleaning schedules for the physical structure, equipment and all other areas of the facility. This should detail: Frequency Responsibility All defined methods and procedures Individual accountability The product used, strength &/or dilution, contact and rinse times. 3.0 OPERATIONS AND FACILITYGUIDELINES / EVIDENCECOMMENTS3.1A maintenance related food safety programme is established and records are maintained. A procedure for reconciling parts after maintenance is performed. (All parts should be accounted for. Any missing parts or pieces of equipment should be immediately brought to the attention of management.) A procedure for ensuring that proper cleaning and sanitation occurs before equipment is placed back into service following maintenance Records to show sign off at each stage of the procedure by maintenance, cleaning and production personnel.A formal preventive maintenance program and work order system was in use to prioritize the elements of identified structural, equipment, or utensil maintenance problems that could cause food adulteration. Work orders were prioritized as “do immediately” or within a 24-hour period, based on the impact upon food safety and production. 3.0 OPERATIONS AND FACILITYGUIDELINES / EVIDENCECOMMENTS3.2The facility is registered with the appropriate food safety enforcement body, where required by legislation.Where local legislation requires the premises to be registered or licensed by an enforcement body (e.g. UK registration with the local Environmental Health Department), evidence must be available to confirm that this has been done. Registered by CIQ .The no. is 3700/08405.3.3The facility is approved for export to the EU (where required).For products (e.g. Meat) which require Export approval for EU markets, evidence of this approval must be available.We only produce vegeteble and fruits products3.4Is any part of the operation undertaken at a separate site?This separate location may also need approval as 3.2 & 3.3 aboveNo.4.0 GOOD MANUFACTURING PRACTICES GUIDELINES / EVIDENCECOMMENTS4.1Good Manufacturing Practices programme is established (including visitor and training programmes). GMP standard clearly defined GMP self-audits are conducted regularly and include timely corrective action. Guidelines for visitors and contractors Training recordsThe company had established written employee and Good Manufacturing Practices (GMPs) policies. Specific written procedures were on file for providing food safety training to all personnel, including temporary personnel ,visitors and contractors. Records of training completion for new employees and annual refresher training documentation were maintained for all personnel. 5.0 PRODUCT PROTECTIONGUIDELINES / EVIDENCECOMMENTS5.1A Glass and brittle plastic policy is in place. Glass & brittle plastic register Procedure to define how glass and brittle plastic breakages are controlled. The condition of glass & brittle plastic items is regularly monitored at an appropriate frequency based on risk. Contamination risks are identified and removed / repaired.A written policy stating that no glass or brittle plastics were to be used in the facility, except where absolutely necessary, was in place. Included in the policy was a procedure to handle any glass breakage in the facility. A list of all essential glass had been developed and was audited on a routine frequency to ensure that any accidental breakage was found and addressed. Daily checks were conducted of the workshop essential glass and all other areas were checked weekly. In general, the audit appeared thorough. 5.0 PRODUCT PROTECTIONGUIDELINES / EVIDENCECOMMENTS5.2Foreign material control methods are used Such asMetal detectionX-rayLine strainersOthersState size / strength /sensitivity and location in process For all H. J. Heinz purchased food products, appropriate foreign material controls must be in place, positioned as close to the final packaging as possible and in working condition. Traps, screens, metal detectors, magnets and reject systems should be regularly monitored. The results and corrective action must be recorded. Rare Earth (Neodymium Iron Boron) magnets must be utilised where appropriate. Magnets should be checked for strength at annual intervals with a gauss meter and replaced if they have lost more than 10% of their specified design strength. Metal detection devices should have a product rejection device and/or a procedure for an alarm or belt shut off mechanism. Water and steam is filtered through 100 micron sieve at point of use when water is used as an ingredient, or steam injected into the product Pens used in production areas must be metal detectable.Metal detection devices are used and have a procedure for an alarm or belt shut off mechanism.Water and steam is filtered through seive.Pens used are metal detectable.6.0 PRODUCT QUALITYGUIDELINES / EVIDENCECOMMENTS6.1Laboratories are accredited by a competent authorityState accreditation body. Accreditation by accredited agency e.g. in the UK UKAS or CLAS, must cover all tests required. Certification of test methods and operating procedures Methods to be comparable to those required by H.J.Heinz Calibration and Training of laboratory personnel Lab is accredited by CIQ.Lab personnel are trained and calibrated regularly.There are enough state methods and operating procedures,and reports are filed for required time.7.0 PRODUCT, INGREDIENT AND MATERIAL TRACKINGGUIDELINES / EVIDENCENote For legal reasons, UK records must be kept for the shelf life of the product plus one year7.1Full traceability from raw materials through to finished product. Traceability system tested at least annually, included as part of recall exercise defined in 7.2A written recall program was on file. All finished products were coded. Product traceability was accomplished through the recording of raw material lot numbers on production records, and included source identification for work in progress and rework. Distribution records were maintained to identify the initial point of distribution to facilitate segregation and recall of specific lots. The recall program was tested every six months with appropriate documentation maintained on file. The date of the last such exercise was February 6, 2004. In order to fully test the system, it was recommended that deliberately difficult mock recall scenarios be selected.7.2A documented recall/withdrawal programme is established. A documented recall/ withdrawal programme A supplier recall contact list with alternatives for 24 hour/7 day a week availability. Defined responsibilities for disposition and reconciliation of recovered product, Annual testing of the programmes effectiveness8.0 PURCHASING AND CONTROL OF INCOMING INGREDIENTS GUIDELINES / EVIDENCEUse Ingredient specifications from all HJH affiliates and other site supporting informationCOMMENTS8.1An approved supplier programme is established for all ingredients and packaging materials. This should include periodic verification of compliance to specification(s). There is a documented procedure, which indicates the process steps that must be completed to approve a raw material or packaging supplier. This should be Risk Assessment based. Suppliers performance is monitored as part of the programme. When Certificates of Analysis and letters of guarantee are used, the supplier should periodically verify compliance to the specifications. The approved supplier list is maintained current. A written program to evaluate and select suppliers of goods and services that affect product quality and food safety had been implemented. An approved list of these suppliers was maintained, as well as copies of ISO certificates, HACCP certificates and letters of guarantee for packaging8.2Procedures for inspection, approval and disposition of ingredients and packaging materials are established. Sampling procedures, testing frequency, and testing methods for incoming materials are clearly defined and documented. A procedure should be established which places materials on-hold until the appropriate QC inspections can be made - a positive hold-release programme. 9. CONTROL OF NON-CONFORMING ITEMSGUIDELINES / EVIDENCECOMMENTS9.1Facility has established procedures for the identification, segregation and disposition of non-conforming raw materials, packaging and finished products. Records are maintained Procedures to control non-conforming items All records are present and complete. Segregation does not have to be physical but must be effective.Written procedures were in place to control nonconforming product, including work in progress, finished product, and returned goods. A separate freezer was utilized for “nonqualified” product. Corrective actions equal to the seriousness of the risk appeared to be taken. Records were kept of the corrective actions and disposition of the product. The disposition records accounted for the total quantity of the nonconforming material produced10. PROCESS CONTROL GUIDELINES / EVIDENCECOMMENTS10.1Procedures are established, including schedules and frequency, for the calibration and accuracy of key measurement and testing equipment, for labs, QC and manufacturing. Records are maintained. A process exists for establishing and maintaining calibration and accuracy of key testing equipment. This should include frequency of calibration and reference standards. Known standards or external verification are used where appropriate. Records indicate calibration is as specified.Any measurement identified as a Critical Control Point must be carried out using traceable calibrated equipment. A calibration program was in place for all thermometers,electronic scales and metal detectors. The thermometer used as a standard was certified annually by the government. Daily checks of thermometer were conducted against the standard thermometer. As a further validation, it was recommended that thermometers be routinely calibrated using ice water to provide a 0 standard.10. PROCESS CONTROL GUIDELINES / EVIDENCECOMMENTS10.2An effective preventative maintenance programme is established. Records are maintained. There is an effective programme for preventative maintenance that includes responsible parties, tasks and frequency. There should be an effective method of identifying maintenance needs and verifying maintenance has been performed. Preventative maintenance takes place according to defined schedules. Equipment maintenance records are kept. an inventory management system to ensure that an adequate supply of parts is maintained A formal preventive maintenance program and work order system was in use to prioritize the elements of identified structural, equipment, or utensil maintenance problems that could cause food adulteration. Work orders were prioritized as “do immediately” or within a 24-hour period, based on the impact upon food safety and production.It maintain an adequate budget and support to maintain the proper and timely acquisition of appropriate tools, materials, equipment, monitoring devices, chemicals, and pest control materials11. CONTINUOUS IMPROVEMENTGUIDELINES / EVIDENCECOMMENTS11.1A quality awareness programme is in place, which includes the defined vision or mission for the organisation.Eg Quality policy The vision or mission statement of the organisation should be clearly defined and communicated to all levels. Quality awareness should be evident throughout the organisation. The mission statement shall be endorsed and signed by senior management and be reviewed at a frequency not exceeding two years. There should be an ongoing formal exchange of quality information. A Quality Manual had been developed. This manual included work instructions and/or job descriptions outlining the specific responsibilities of each department manager and employees, a Quality Policy, and written policies for the programs listed in the AIB Consolidated Standards for Food Safety11.2Procedures are established for undertaking Management Review. Records are maintained.Supplier shall use established procedures to proactively monitor Key Quality Indicators in order to drive continuous improvement. Management Review shall be undertaken by senior management Management Review shall include, as a minimum, the following: Review of customer complaints Review of non-conforming product occurrences Review of internal and third party audit non-compliances Review of process performance and product conformity Review of staff changes and effect on delivery of Quality System requirements Review of recommendations from Ongoing Quality Improvement teams Review of Preventative actions Review of corrective actions and their completionA monthly self-inspection program is in use, and systems and procedures critical to product safety and quality were audited twice-yearly as part of a regularly scheduled management review to ensure they were in place, appropriate, and complied with. 11. CONTINUOUS IMPROVEMENTGUIDELINES / EVIDENCECOMMENTS11.3Procedures are established for internal assessments based on H