Golden Six. CII-Master Class 2 nd Dec-2015, New Delhi Harshad Pathak

Transcription

1 Golden Six CII-Master Class 2 nd Dec-2015, New Delhi Harshad Pathak

2 Take Home messages the juice.. Golden Six is Common sense ( Caution it is not always common) Simple tool to identify the themes / patterns in food safety Preventive measure to drive Continuous improvement Our senses are our tools Our wisdom is our skill To Fulfil our purpose Nourishing families so they can flourish and thrive

3 Agenda What are the Golden Six? A simple way of looking at a plant s overall food safety conditions How does the process work? It starts from the outside and moves in What are the key indicators? Red Flags and Out of Compliance Indicators Practical Implementation in factory Questions

4 .a bit of History Why was Golden Six created The Golden Six was created as a way to simplify the many requirements for a food manufacturing facility The idea was to boil down requirements to the very basic expectations for food plants This was done using feedback from regulatory inspections, internal inspections and CODEX requirements A Golden Six assessment can be done relatively quickly to provide an overall view of a plant s food safety conditions

5 What is Golden Six? Let s keep it simple 6 Basics of Food Safety to check out, more the Red Tags better S

6 Golden Six

7 Important Tip Are we seeing the same thing? Get Calibrated, learn to connect the dots

8 What should we look for? Devil is in the details Key Out of Compliance Indicators Why do we hate water? Because Pathogens loves them Single most effective way to avoid any microbial growth in lines and environment Any external water coming inside the factory is direct contamination of Pathogens What s wrong with pests? They bring in Pathogens They contaminate our products Ethnic foods issue Cereals are prone to insect infestation What does this tell us? They bring in Pathogens They contaminate our products Ethnic foods issue Cereals are prone to insect infestation

9 What should we look for? Devil is in the details Key Out of Compliance Indicators Why do they indicate? They carry pathogens through hands They carry pathogens through shoes and materials Can contaminate with foreign matter Allergen contamination What s wrong with this? Foreign material contamination Microbiologic al contamination Breeding of microbes Allergen contamination What does this tell us? Foreign material contamination Pest entry and contamination Breeding of microbes Allergen contamination

10 How does that work?

11 Score Card Helps to determine a pattern Theme could be a requirement or a specific area

12 The Process of Golden Six How we use them in our facilities

13 Golden Six How we have implemented

14 Must do s activities visuals Compliance check to GMP & PPE s

15 Daily Must Do s trending EHS Must do s Safety Goggle Ear Plug 17% 48% 53% 47% 74% 6 Jun Jul Aug Sep Oct Nov Dec Safety Shoes Jun Jul Aug Sep Oct Nov Dec Green Yellow Red Green Yellow Red Q&FS Must do s Hair net 7% 55% % 47% Jun Jul Aug Sep Oct Nov Dec Green Yellow Red 3% No Jewelry 43% 83% Jun Jul Aug Sep Oct Nov Dec Green Yellow Red No loose object above waist % No observation = < 2 observations > 2 observations Days Jun Jul Aug Sep Oct Nov Dec Green Yellow Red

16 Till Date G6 trending The visual monitoring keep action live. % of Green, Yellow and Red overall days period wise for 2015

17 G6 trending Measurement of every bucket for effective actions Water control Pest control Sanitation & Housekeep % 33% 48% 39% 11% 13% 61% 62% 27% 12% 31% 8% 57% 29% 52% 39% 14% 1 62% 31% 8% 54% 35% 12% 39% 36% P1 P2 P3 P4 P5 P6 P7 P8 P9 P10 24% 56% 22% % 65% 73% 35% 27% 81% 96% Employee practices Overhead cleaning Condition of Bldg / equ 9 77% 85% 76% 78% 15% 8% 19% 12% 6% 15% 9% 11% 4% 11% 3% 8% 4% P1 P2 P3 P4 P5 P6 P7 P8 P9 P % 39% 52% 58% 62% 42% 23% 54% 39% 58% 62% 65% 58% 44% 15% 7% 9% 7% 6% 11% 3% P1 P2 P3 P4 P5 P6 P7 P8 P9 P10 35% 38% 35% 39% % 67% 63% 58% 54% 54% 52% 42% 46% 44% 39% 25% 33% 22% 23% 3 27% 3 22% 17% 19% 19% 21% 18% 19% 15% 9% 8% 3% P1 P2 P3 P4 P5 P6 P7 P8 P9 P % 67% 59% 58% 57% 65% 54% 58% 54% 52% 41% 43% 46% 42% 39% 42% 39% 33% 27% 24% 4% 6% 8% 4% 3% 3% P1 P2 P3 P4 P5 P6 P7 P8 P9 P % 74% 82% 81% 79% 68% 64% 69% 58% 56% 23% 26% 19% 17% 21% 22% 12% 19% 15% 7% 19% 12% 12% 14% 9% 6% 6% 4% P1 P2 P3 P4 P5 P6 P7 P8 P9 P10

18 G6 findings & Action Tracker Every action & accountability tracked.. Period P10 Period P10 Period P10 STATUS (All) STATUS closed STATUS (Multiple Items) Row Labels Count of Nature of finding Row Labels Count of Nature of finding Row Labels Count of Nature of finding Condition of bldg /equip 86 Condition of bldg /equip 42 Condition of bldg /equip 44 GMP practices 60 GMP practices 37 GMP practices 23 Overhead food stream 16 Overhead food stream 8 Overhead food stream 8 Pest Control 6 Pest Control 5 Pest Control 1 Sanitation / Housekeeping 29 Sanitation / Housekeeping 22 Sanitation / Housekeeping 7 water control 12 water control 8 water control 4 Grand Total 209 Grand Total 122 Grand Total 87 Period P10 Period P10 Period P10 STATUS (All) STATUS closed STATUS Pending Row Labels Count of Nature of finding Row Labels Count of Nature of finding Row Labels Count of Nature of finding Ashok M 97 Ashok M 54 Ashok M 43 Nilesh A 9 Nilesh A 6 Nilesh A 3 Rupesh 7 Rupesh 7 Sangram 1 Sangram 1 Shyam 1 Shyam 3 Shyam 4 Rajesh K 11 (blank) 2 (blank) 2 Sandeep R. 1 Rajesh K 4 Rajesh K 15 Prashant K 1 Nitin N 1 Sandeep R. 1 Vijay G 7 Prashant K 5 Nitin N 1 Manish J. 1 Rupesh 1 Prashant K 6 Sandeep R 6 Manish J. 1 Vijay G 7 pramod w 6 Sandeep R 2 Rupesh 1 Rupesh s 3 Shilpika J 5 Manish J. 2 Rajesh/Vijay 4 pramod w 7 Sandeep R 8 Hemant 1 Rajesh k. 1 Shilpika J 5 Rajesh K/Vijay G 1 Rupesh s 1 pramod w 13 Rajesh 1 Rajesh/Vijay 1 Rajesh k. 1 Rupesh/Santosh 1 Jitendra K 1 Rupesh s 4 Sonavane B. 1 Amit/Rajesh K/Vijay G 1 Rajesh/Vijay 5 Rajes K 1 Rajes K 1 Jitendra K 1 Rajesh v 2 Bharat S 2 Amit/Rajesh K/Vijay G 1 Rupesh S/Santosh 3 Hemant S 1 Hemant 1 Santosh & Rajesh K 1 Grand Total 87 Rajesh K/Vijay G 1 Sandeep R & Santosh G 2 Rajesh 1 Grand Total 122 Rupesh/Santosh 1 Sonavane B. 1 Rajes K 2 Rajesh v 2 Rupesh S/Santosh 3 Bharat S 2 Santosh & Rajesh K 1 Sandeep R & Santosh G 2 Hemant S 1 Grand Total % closure of the points

19 G6 Visual Trend Visual trend to target specific area

20 Finally it is Culture Do you know where are you on this maturity journey Golden Six Helps Here

21 Questions? Thank You for your attention