Model Curriculum. Pulse Processing Technician SECTOR: SUB-SECTOR: OCCUPATION: REF ID: NSQF LEVEL:

Transcription

1 Model Curriculum SECTOR: SUB-SECTOR: OCCUPATION: REF ID: NSQF LEVEL: FOOD PROCESSING FOOD GRAIN MILLING PROCESSING FIC/Q1004, V1.0 4

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3 TABLE OF CONTENTS 1. Curriculum Trainer Prerequisites Annexure: Assessment Criteria 10

4 Pulse Processing Technician CURRICULUM / SYLLABUS This program is aimed at training candidates for the job of a, in the Food Processing Sector/Industry and aims at building the following key competencies amongst the learner Program Name Qualification Pack Name & Reference ID. ID FIC/Q1004, v1.0 Version 1.0 Version Update Date 15/02/2016 Pre-requisites to Training Training Outcomes Preferably Class 10 and 2-3 years experience in Milling The programme will help in building the following key competencies amongst the learner: Prepare different types of dough used in making baked products; Carry out the milling processes for all types of grains; Handle various milling machineries while maintaining process parameters; Plan production schedule; Organize raw material for the production process; Inspect raw materials and finished goods for quality and quantity; Observe food safety and hygiene standards at work; Demonstrate troubleshooting skills.

5 This course encompasses 5 out of 5 National Occupational Standards (NOS) of Pulse Processing Technician Qualification Pack FIC/Q1004, Version 1.0 issued by Food Industry Capacity and Skill Initiative. Module Key Learning Outcomes Equipment Required 1 Introduction to the training program 01:00 00:00 Introduce each other and build rapport with fellow participants and the trainer. White board/chart papers, marker Bridge Module 2 Overview of the Pulse Processing Technician Role 01:00 Understanding the roles and responsibilities of pulse processing technician Awareness of the nature and availability of job opportunities Laptop/computer white board, marker, projector, chart papers 00:00 3. Introduction to the Food Processing Industry 01:00 Define food processing List the various sub-sectors in food processing industry Laptop/computer white board, marker, projector, chart papers, Trainer s Guide, Student handbook 00:00 4. Introduction to Food Grain Milling Sector 04:00 State the need for food grain milling process State the common methods of milling food grains State the process of milling various types of grains List the terminology used in milling process Laptop, white/black board, marker, chart papers, projector, trainer s guide, student handbook, pictures/charts of different types of pulse milling

6 Module Key Learning Outcomes Equipment Required 02:00 5. Organizational standards and norms 08:00 04:00 6. Prepare and Maintain Work Area and Process Machineries 04:00 08:00 FIC/N1011 State the roles and responsibilities of pulse processing technician in a commercial grain milling unit State how to conduct yourself at the workplace State the personal hygiene and sanitation guidelines State the food safety and hygiene standards to follow in an organization Describe the organisation standards, process standards and procedures followed Describe the provision of wages, working hours and accident compensation as per organisation policy Describe the internal processes like procurement, store management, inventory management, quality management and key contact points for query resolution Dispose waste materials as per organisation standards State the code of business conduct Describe the dress code to be followed Explain the types of products produced by the organisation Identify the machines and tools required for the milling process Select and set the machines and tools required for production Demonstrate the use of different tools and machineries used in the milling process List the types of raw materials (various pulses) and products obtained from each raw material List the types of chemicals, materials and equipment required for cleaning and maintenance Explain the supplier / manufacturer s instructions related to cleaning and maintenance Assess the working and performance of all machineries and tools used for the food grain milling process Laptop, white board, marker, chart papers, projector, trainer s guide and student handbook, protective gloves, head caps, aprons, safety goggles, safety boots, mouth masks, sanitizer, safety manual Laptop, white board, marker, chart papers, projector, trainer s guide and student handbook, authorized sanitizers, cleansers, all equipments for demonstration

7 Module Key Learning Outcomes Equipment Required Attend to the minor repairs/ faults of all machines, if required Ensure that work area is safe and hygienic for food processing Keep the work area free from debris Maintain the cleanliness of the work area ensure that it is free from pests Place the necessary tools required for process Explain cleaning the machineries and tools used with recommended sanitizers following the company specifications and standards Describe the cleaning process to disinfect equipment/ tools Clean the work area using recommended sanitizers Explain the method of using the ERP system Entering details in the ERP system followed by the organisation 7. Preperation for Production 05:00 10:00 FIC/N1012 Revise raw materials and products State the types of machineries used in processing and machineries used in the organisation Describe the milling machines flow process Demonstrate handling all machineries Outline basic principles of mathematics Describe how to calculate the process time for effective utilization of machineries Explain how to plan batch size considering full capacity utilization of equipment Explain how to calculate of raw material for required quantity of finished product Calculate raw material for required quantity of finished product Read and understand the production order from the supervisor Plan batch size considering full capacity utilization of equipment Calculate the process time for effective utilisation of machineries Plan to utilize equipment for multiple products without affecting the quality of the finished products, and to optimise production Allocate responsibilities to the assistants and helpers SOP, Sieve/sorters; White/Black board/ Chart paper, Markers/ computer and projector, Trainer Guide, Student Handbook, Different types of pulses, work flow diagram/chart, SOP, spatulas, packing wrap rolls, measuring cup and spoons, utensils, digital hygrometer, Measurement Cane Cleaner/grader; Conditioning machine; De-husk machine; Splitter machine; Drier; Packaging machine; Grinding machine; Sifter, Bran separator machine, polishing machine, multicrop decorticator, protective gloves, head caps, aprons, safety shoes, mouth cover, safety goggles, food safety manual

8 Module Key Learning Outcomes Equipment Required 8. Operating Grain Mill 07:00 12:00 FIC/N1013 Describe process chart/ product flow chart Explain process for producing each product Plan batch size considering full capacity utilisation of equipment Calculate the process time for effective utilisation of machineries Plan to utilise equipment for multiple products to optimize production and saving energy State quality parameters, basic food microbiology and quality assessment based on physical parameters Evaluate the conformance of raw material quality to company standards, through physical analysis or by referring the quality analysis report from the supplier / internal lab analysis report Describe maintenance of process equipment State the supplier /manufacturer s instructions related to machineries Demonstrate the process of pulse processing Weigh the pulses and transfer to the rotary screen cleaner/graders for cleaning Move the pulses the rotary screen cleaner/grader. Operate the elevator to move the pulses to the cleaner/grader to remove impurities such as light particles, dust and smaller grains. Transfer the pulses to de-stoner and control speed of the destoner to remove stones. Weigh the pulse for further processing. Explain the conditioning science. Transfer the clean pulses to emery rollers for (scratching/pitting) process. Fill and maintain the level of conditioning agents. Maintain the quantity of conditioning agent required for each pulse following the process chart. Maintain the speed of conveyor. Adjust and control speed of the agitator. Maintain soaking time as followed by the organization. SOP, Sieve/sorters; White/Black board/ Chart paper, Markers/ computer and projector, Trainer Guide, Student Handbook, Different types of pulses, work flow diagram/chart, SOP, spatulas, packing wrap rolls, measuring cup and spoons, utensils, digital hygrometer, Measurement Cane Cleaner/grader; Conditioning machine; De-husk machine; Splitter machine; Drier; Packaging machine; Grinding machine; Sifter, Bran separator machine, polishing machine, multicrop decorticator, protective gloves, head caps, aprons, safety shoes, mouth cover, safety goggles, food safety manual, logbooks

9 Module Key Learning Outcomes Equipment Required Repeat the conditioning and drying process several times depending on the type of pulse and standards followed by organisation to loosen the husk. Examine and feel the conditioned pulse and transfer to the drier. Dry the conditioned pulse in the dryer or under sun. Adjust controls of the drier to set the temperature and time. Repeat the drying process several times depending on the type of pulse and standards followed by organisation to loosen the husk. Transfer the conditioned pulses into the emery coated roller mill to remove/separate outer shell (husk) of the pulses. Manipulate the rollers to achieve desired clearance. Maintain the speed of the aspirator fan to remove husk and to separate de-husked pulse. Weigh the de-husked pulse and transfer to the next level. Manipulate the rotation of the rotary blades of the splitter machine to split de husked pulse to produce dal. Sort the split dal in sorting machine based on size, colour, etc. Polish the split dal in the polisher Polish the split dal with oil and water polisher. Dry the polished dal in the drier. Transfer finished products (dal) to packing machine. Arrange the batch code, date coding, and filling quantity in the packaging machine. Pack the finished product as per organisation standards. Check the weight of the packed product. Store the packed product according to the specifications and standards of the organisation. Weigh the cleaned dal for grinding. Change the mesh screens of the grinder to meet the standards of the final product. Transfer the dal into the feed hopper of the grinder.

10 Module Key Learning Outcomes Equipment Required Manipulate feed chutes to regulate flow of dal through machine hopper into grinders. Adjust the clearance between each rollers of roller mill by turning wheels according to dal size and hardness. Manipulate controls to regulate speed, to obtain required fineness and to achieve maximum yield. Control the heat of grinder by circulating water. Collect the flour in the collecting bin. Confirm the quality of the flour through physical parameters. Weigh the flour and transfer to the sifter to achieve required fineness. Adjust the mesh screens of the sifter to required fineness. Manipulate slides in spouts to route pulse to sifters. Collect the sifted flour. Assess the quality of flour through physical parameters. Weigh the flour produced. Read and understand the work order and process flow chart. State pre-cleaning process. Operate conveyor to transfer pulses from de- stoner to conditioning bin. Preparing and conditioning the pulses. Manipulate valve to control speed and amount of the grain conveyed into drier. Managing drying the grain. Repeat the conditioning and drying process several times depending on the type of pulse and Operating husking machinery. Manage polishing of pulses. Operate length graders to grade processed pulses. Operate sifter to remove broken grains. Manipulate machinery by feeling the grain and ensure that the grain is processed in accordance with specifications. Calculate and weigh the grain before and after processing. Explain the conveyor system and different types of conveying.

11 Module Key Learning Outcomes Equipment Required Operate the conveyor/elevator and transfer the grain from one processing machine to other. Clean the machineries and work area using recommended sanitizers. Maintain the work area to keep it pest free. Explain the cleaning procedures like (CIP) and (COP). Indicate knowledge on sanitizers and disinfectants. Describe attending minor repairs of all machines. Maintain equipment following daily/weekly maintenance schedules as per suppliers instructions/manuals. Ensure timely follow up with annual maintenance contractor. Report issues (if any) related to all processes, to the supervisor and implement. Suggest corrective action. 9. Complete documentation and record keeping 04:00 06:00 FIC/N1014 Documentation system followed in the organization such as production chart, process chart and finished goods chart; State the methods to document and maintain records of observations (if any) related to raw materials, process and finished products. Describe recording details of all raw materials used in the production and document, as per company standards; Maintain records of observations related to raw materials and packaging. Load the finished product details in ERP for future reference; Assess the documents and track them from finished product to ingredients, in case of quality concerns and for quality management system audit. Describe the process of documenting production plan with details such as the product details, production sequence, equipment and machinery details, efficiency and capacity, utilization of equipment; Describe the process of documenting process parameters as Laptop, white board, marker, chart papers, projector, trainer s guide and student handbook, logbooks, internal audit register, food safety manual, quality policy etc.

12 Module Key Learning Outcomes Equipment Required applicable for the entire production in process chart or production log for all products produced; Maintain document of batch size, production yield, wastage of raw materials, energy utilization and final products produced; Maintain record of observations. Maintain records on the types of finished products produced; Describe the documents prepared for the finished products details such as batch number, time of packing, date of manufacture, date of expiry, other label details, primary and secondary packaging materials for all finished products, storage conditions etc. as per company standards; Maintain a record of observations or deviations (if any) related to finished products. 10. Food Safety, Hygiene and Sanitation 06:00 12:00 FIC/N9001 State the importance of safety, hygiene, and sanitation in food processing industry Observe the industry standards to maintain a safe and hygienic workplace Detail the principles of HACCP Follow HACCP principles to eliminate food safety hazards in the process and products; State the possible physical, chemical and biological hazards and methods of prevention of various hazards Follow industry standards like product recall process State food laws and regulations on product, packaging and labelling State food laws and regulations Describe the knowledge on legal regulations pertaining to work place like health and safety, recommended dosage for use of sanitizers, control of substances hazardous to health, handling/storage/ disposal/ cautions of use of sanitizers and disinfectants, fire precautions, occurrences, hygiene practice, disposal of waste, environmental protection, etc. Exercise personal hygiene by using gloves, hairnets, masks, ear plugs, goggles, shoes, aprons, etc. Board/Chart paper/ Laptop and Projector, Trainer Handbook, Participant handbook, etc., Sanitizers, Protective Gloves, Protective Gloves, aprons, headmasks, safety goggles, safety shoes, internal audit, logbooks, quality manual, food safety manual.

13 Module Key Learning Outcomes Equipment Required Explain using safety equipment such as fire extinguisher, first aid kit and eye-wash station, when required Construct workplace checklist audits before and after work to ensure safety and hygiene Describe food safety and hygiene practices Describe following hygienic production of food by Construct workplace checklist audits before and after work to ensure safety and hygiene State the importance of documenting and maintaining records for the credibility and effectiveness Determine the quality of food using sensory parameters criteria and take immediate measures to prevent spoilage; Explain storing raw materials, finished products, allergens separately to prevent cross contamination Describe labelling raw materials and finished products and storing in designated storage areas according to safe food practices; Follow stock rotation based FEFO / FIFO. State the importance of cleaning, and maintaining machineries and follow the checklist. Describe the storage norms for raw materials, packaging material and finished products; Explain stock rotation of ingredients and finished products based on FIFO and FEFO; Exercise storing raw materials, finished products, allergens separately to prevent cross contamination Label raw materials and finished products and store in designated storage areas according to safe food practices Explain quality parameters and quality assessment based on physical parameters, basic food microbiology 11. Field Visits Observe the factory location, layout and safety aspects of food processing All the tools and equipment listed above

14 Module Key Learning Outcomes Equipment Required 05:00 20:00 Observe the storage facilities for raw materials and finished products Observe the various machineries used in pickle processing Observe the various machineries used in pickle processing Observe the cleaning methods and processes followed to maintain the process machineries and tools Observe the raw materials used and their storage procedures Observe the packaging and storage processes of raw material and finished product Observe the post-production cleaning and maintenance process followed in the industry. Observe the various machineries used in the milling process; Observe the ERP (Enterprise Resource Planning) system and the documentation process. Observe the production process for various products; Observe the quality parameters and quality assessment; Observe the types of machines used in the organisation. must be available at the site of field visit 12. Revision 01:00 Revised the knowledge gained so far All the tools and equipment listed above must be available at the time of revision 03: Evaluation 06:00 20:00 Assess the knowledge and skills acquired by the participants All the tools and equipment listed above must be available for evaluation

15 Module Key Learning Outcomes Equipment Required Total Duration 150:00 53:00 97:00 Unique Equipment Required: Samples of various Pulses; spatulas, packing wrap rolls, measuring cup and spoons, utensils, digital hygrometer, Measurement Cane, weighing balance, silos Cleaner/grader; Conditioning machine; De-husk machine; Splitter machine; Polisher; Drier; Packaging machine; Grinding machine; Sifter;,, Bran separator machine, multicrop decorticator different type of sanitizers, disinfectants, cleansers, protective gloves, head caps, aprons, safety shoes, mouth cover, safety goggles, food safety manual, quality manual Grand Total Course Duration: 150 Hours, 0 Minutes Recommended OJT Hours: 20 Hours, 0 Minutes (This syllabus/ curriculum has been approved by SSC: Food Industry Capacity and Skill Initiative) Trainer Prerequisites for Job role: mapped to Qualification Pack: FIC/Q1004, v1.0 Area Details 1 Description To deliver accredited training service, mapping to the curriculum detailed above, in accordance with the Qualification Pack FIC/Q1004, Version Personal Attributes An aptitude for conducting training, and pre/ post work to ensure competent, employable candidates at the end of the training, and pre/post

16 3 Minimum Educational Qualifications 4a 4b Domain Certification Platform Certification work to ensure competent, employable candidates at the end of the training. Strong communication skills, ability to work as part of a team; a passion for quality and for developing others; well-organized and focused, eager to learn and keep oneself updated with the latest in the mentioned fields. B.Sc /B.Tech/BE or PG Diploma in Food Process Engineering/ Grain Milling with 2-3 years of hands on experience in a Milling Industry M.Sc /M.Tech/ME or PG Diploma in Food Engineering/ Grain Milling with 1-2 years of hands on experience in a Milling Industry Certified for Job Role: mapped to QP: FIC/Q1004, v1.0. Minimum accepted score is 80% Recommended that the Trainer is certified for the Job Role: Trainer, mapped to the Qualification Pack: SSC/Q1402. Minimum accepted score is 80 % as per FICSI guidelines. 5 Experience B.Sc /B.Tech/BE or PG Diploma in Food Engineering/ Grain Milling with 2-3 years of hands on experience in a Grain Milling Unit M.Sc /M.Tech/ME or PG Diploma in Food Process Engineering/ Grain Milling with 1-2 years of hands on experience in a Grain Milling Unit

17 Annexure: Assessment Criteria Assessment Criteria Job Role Qualification Pack FIC/Q1004, v1.0 Sector Skill Council Food Processing Guidelines for Assessment 1 Criteria for assessment for each Qualification Pack will be created by the Sector Skill Council. Each Performance Criteria (PC) will be assigned marks proportional to its importance in NOS. SSC will also lay down proportion of marks for Theory and Skills Practical for each PC. 2 The assessment for the theory part will be based on knowledge bank of questions created by the SSC. 3 Individual assessment agencies will create unique question papers for theory part for each candidate at each examination/training centre(as per assessment criteria below) 4 Individual assessment agencies will create unique evaluations for skill practical for every student at each examination/training canter based on this criteria 5 To pass the Qualification Pack, every trainee should score a minimum of 70% (overall) in every QP 6 The marks are allocated PC wise; however, every NOS will carry a weight age in the total marks allocated to the specific QP

18 Assessable Outcome 1. FIC/N1011: Prepare and maintain work area and process machineries for milling pulses 2. FIC/Q1012: Prepare for production of pulses Assessment Criteria PC.1 Prepare, clean and maintain the cleanliness of the work area using approved sanitizers and keep it free from dust, waste, flies and pests PC2. Ensure that the work area is safe and hygienic for food PC3. Dispose waste materials as per defined SOPs and industry requirements Total Mark (500) Out Of Marks Allocation Theory Skill s Prac tical PC4. Check the working and performance of all machineries and tools used such as de-stoner, de-huller, polisher, blender, pulverizer, stone mill / roller mill, sifter, packaging machines, etc. PC5. Clean the machineries and tools used with approved sanitizers following SOP PC6. Place the necessary tools required for process PC7. Attend the minor repairs/ faults of all machines, if required PC8. Select and set the machines and tools required for production Total PC1. Read and understand the production order from the supervisor PC2 Check the availability of raw material, packaging materials, equipment and manpower PC3. Support in planning production sequence based on PC4. Plan batch size considering full capacity utilization of equipments PC5. Calculate the raw material requirement (considering the process loss) to produce the required quantity of finished product(s) PC6. Calculate the raw material, packaging materials and manpower requirement for completing the order PC7. Ensure the working and performance of each equipment required for the process PC8. Calculate the process time for effective utilization of machineries PC9. Plan batch size considering full capacity utilization of equipments PC10.Plan to utilize equipments for multiple products without affecting the quality of 3 1 2

19 3. FIC/Q1013: Carry out milling of pulses the finished products, and to optimize production and saving energy PC11.Allot responsibilities/ work to the assistants and helpers PC12.Refer to the process chart/ product flow chart for pulses being milled PC13.Weigh the raw materials required for the batch PC14.Check the conformance of raw material quality to company standards, through physical analysis or by referring to the quality analysis report from the supplier/ internal lab analysis report PC15.Clean the screens /sieves PC16.Lubricate machineries for smooth functioning PC17.Ensure working and performance of required machineries and tools PC18.Keep the tools accessible to attend repairs/faults in case of breakdown Total PC1. Read and understand the production order from the supervisor PC2. Weigh the legume/pulse required for the batch PC3. Transfer pulses to the unloading area and dump manually into the precleaner separator or and transfer to elevator, operate elevator to move the pulses to the pre-cleaner separator to remove the impurities like light particles, dust and smaller grains PC4. Set controls of pre-cleaner/ separator, start machine and to remove the impurities like light particles, dust and smaller grains, collect cleaned grains from the discharge chute PC5. Transfer the pulse to de-stoner manually or by adjusting conveyor speed, set controls of de-stoner like speed to remove the stones from pulses, collect destoned pulse from the discharge chute PC6. Transfer the cleaned pulses to emery rollers (containing set of rubber rollers) to break the tip of the pulses /crack/scratch the pulse for better penetration of oil and water during soaking / conditioning (scratching/pitting) process PC7. Fill and maintain the level of conditioning agents like water, oil, etc. for spraying on the pulse for conditioning

20 PC8. Set and control the quantity of conditioning agent required for conditioning of each pulse following the process chart PC9. Maintain the speed of conveyor to apply conditioning agent on the pulse moving in the elevator PC10.Adjust and control speed of the agitator to mix the conditioning agent with the pulse PC11.Set and maintain soaking / conditioning time following sop, allow to soak for specified time PC12.Check the conditioned pulse and transfer to the drier or to drying area and spread evenly for sun drying PC13.Adjust controls of the drier to set the temperature and drying time to dry the conditioned pulse PC14. Repeat the conditioning and drying process several times depending on the type of pulse and standards followed by organisation to loosen the husk (or) set controls to repeat conditioning and drying cycle (in continuous processing and automated units) PC15.Transfer the conditioned pulses manually (or) by starting and adjusting conveyor speed into the emery coated roller mill to remove/separate outer shell (husk) of the pulses PC16.Adjust the rollers to achieve desired clearance between the rollers to dehusk the pulse PC17.Control the speed of the aspirator fan to remove husk and to separate dehusked / decorticated pulse PC18.Weigh the de-husked pulse and transfer to the splitter machine either manually or by operating the conveyor/elevator PC19.Control the rotation of the rotary blades of the splitter machine to split de-husked pulse (split dehusked pulse into two halves) to produce dhal PC20.Set controls of the sorter machine and transfer split de-husked dhal to sort based on size, colour etc PC21.Transfer the dhal manually or through conveyors to polisher machine (emery cone polisher), adjust rotation of brush roller to polish split dhal or polish the split dhal with oil and water polisher by controlling quantity of oil applied on the dhal

21 PC22.Set controls of drier like temperature and drying time and transfer the polished dhal to drier manually or through conveyors for drying to required temperature PC23.Check the quality of polished dhal through physical parameters sample product and transfer to quality lab for analysis PC24. Weigh the split dhal produced, start conveyors and elevators to transfer finished products (dhal) to packing machine PC25.Weigh dal and transfer to the grinding area PC26.Fix/change the mesh screens of the grinder (pulveriser / plate mill) following sop to achieve required fineness PC27.Transfer the dhal into the feed hopper of the grinder PC28.Open and adjust feed chutes to regulate flow of dhal through machine hopper into grinders, start machine to grind dhal, check the flour for fineness and turn wheels to adjust plates to achieve required fineness PC29.Turn valves to circulate water through grinders to control heat generated while grinding PC30. Collect the flour in the collecting bin and transfer to sieving machine (or) start conveyor and control speed to transfer flour to sieving machine, start sieving machine and control vibration to obtain product of uniform fineness PC31.Check the quality of the flour through physical parameters like colour, texture, fineness etc, sample product and transfer to quality lab for analysis PC32.Weigh flour and transfer to packaging machine (or) start conveyors and elevators to transfer finished products (dhal) to packaging machine PC33.Load packaging materials in the packaging machine and set for filling quantity, batch code, date of manufacture, date of expiry etc PC34.Start packaging machine to pack/bag the finished product as per organisation standards PC35.Check the weight of the packed/bagged product at regular intervals

22 4. FIC/Q1014: Complete documentatio n and record keeping related to milling pulses PC36.Form cartons, place primary packed product in cartons following sop, seal cartons PC37.Transfer packed products to storage area and store maintain storage conditions PC38. Report any issues/discrepancies to the supervisor and implement suggested corrective action immediately PC39.Clean work area, machineries, equipment and tools using recommended cleaning agents and sanitizers PC40. Attend minor repairs/faults of all machines (if any) PC41. Ensure periodic (daily/weekly/monthly/quarterly/hal f yearly/annual) maintenance of all machines and equipment following the SOP or following suppliers instructions/manuals PC1. Document and maintain records of details of raw materials and packaging materials as per organizational standards PC2. Document and maintain record on observations (if any) related to raw materials and packaging materials PC3. Load the raw material details in ERP for future reference PC4. Verify the documents and track from finished products to raw materials, in case of quality concerns and during quality management system audits PC5. Document and maintain records of production plan with details PC6. Document and maintain records of process details for entire production in process chart or production log for all products produced PC7.Document and maintain records of batch size, production yield, wastage of raw materials, energy utilization and final product produced PC8. Document and maintain record of observations or deviations PC9. Load the production plan and process details in ERP for future reference PC10.Verify documents and track from finished product to ingredients, in case of quality concerns and for quality management system audit

23 5. FIC/N9001: Food Safety, hygiene and sanitation for processing food products PC11.Document and maintain records of finished products PC12.Document and maintain records of the finished product details as per organizational standards PC13. Document and maintain record on observations or deviations related to finished products PC14. Load the finished product details in ERP for future reference PC15.Verify the documents and track from finished product to ingredients, in case of quality concerns and for quality management system audits Total PC1. Comply with food safety and hygiene procedures followed in the organization PC2. Ensure personal hygiene by use of gloves, masks,hair net, ear plugs, boots etc. PC3. Ensure hygienic production of food by inspecting raw materials, ingredients, finished products etc for compliance to physical, chemical and microbiological procedures PC4. Pack products in appropriate packaging material, label and store them in designated area free from pests, flies etc. PC5. Clean, maintain and monitor food processing equipments periodically, using it only for the specified purpose PC6. Use safety equipment such as fire extinguisher, eye wash unit, first aid kit when required PC7. Follow housekeeping practices by having designated area for machines/tools PC8. Follow industry standards like GMP, HACCP and product recall PC9. Attend training on hazard management to understand type of physical, chemical and microbiological hazards PC10.Identify, document and report problems such as rodents and pests to management PC11.Conduct workplace checklist audit before and after work to ensure safety and hygiene PC12. Document and maintain raw material, process, packaging material to maintain the effectiveness of quality system

24 PC13.Determine the quality of food using criteria such as odor, color, taste and best before date and take immediate measures to prevent spoilage PC14.Store raw materials, finished products and allergens separately to prevent cross contamination PC15.Label raw materials and finished products and store them in different storage areas according to safe food practices PC16.Follow stock rotation based on FEFO/FIFO Total Grand total Percentage Weightage % 40% Minimum Pass% to qualify (aggregate): 70%

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