PRODUCT QUALITY & SAFETY IN FOOD SUPPLY CHAIN - UNILEVER

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1 PRODUCT QUALITY & SAFETY IN FOOD SUPPLY CHAIN - UNILEVER

2 Quality in Unilever Role of Quality To ensure the design and production of products meet our environmental, consumer safety and quality standards We Manage this through - New product development process with clear product specifications - UL Quality Management System The QMS is verified annually and Quality KPIs are monitored, reported and continuously improved on a frequent and regular basis - A Holistic approach with Business Leaders commitment to drive the culture for Quality excellence from all employees

3 QUALITY SYSTEM ESTABLISHED IN FOOD SUPPLY CHAIN Buying Making Delivery Build Supplier Quality Perfect Quality Execution in Factories with robust Quality system Establish Quality in Logistic We cannot optimize our performance in isolation as part of the overall Quality Strategy we must improve across the extended supply chain

4 1. Build Supplier Quality Background Any supplier can impact our business & reputation.so we have to understand the capabilities and performance of all of them On-shelf Availability Consumer Complaints & Consumer Safety Waste Manufacturing Efficiency Excess Inventory

5 BUILD SUPPLIER QUALITY DESIGN PRINCIPLES Risk-based, reputable, recognized Specification is King Performance measurement Zero-defect mindset

6 2. PERFECT QUALITY IN EXECUTION ROBUST QUALITY SYSTEM FSSC Defines the requirements of food safety management systems + all elements of prerequisite programs + HACCP + interactive communication

7 Components of FSSC 22000

8 Additional requirements Part I requirements to obtain certification Regulatory, Statutory requirements, Code of Practices & Customer requirements Specifications for services Supervision of personnel in application of food safety principles Management of Inputs: A control plan of raw materials shall be in place to confirm product safety. The analyses shall be performed to standards equivalent to those described in ISO Announce, but unscheduled audits of certified organizations

9 2. PERFECT Q IN EXECUTION CONTINUOUS IMPROVEMENT 4M analysis and Methods & Tools Each quality defect we need to make a proper 4M (or 5M, 5M+E) analysis and for each M we need to apply proper countermeasures For each M there is a specific methodology and a specific set of tools. 4 M ANALYSIS MACHINE METHOD MAN MATERIAL 7 Steps of Quality Maintenance 7 Steps of problem solving 5 QUESTION TO ZERO DEFECTS

10 4M Machine 7 Steps of Quality Maintenance 3 main factors of machines quality issues Factor 1 LACK OF BASIC CONDITIONS (MACHINE PARAMATERS NOT RESPECTED, POOR MAINTENANCE IN AM-PM) Factor 2 POOR PROCESS ROBUSTNESS (MACHINE PARAMETERS ARE NOT STABLE AND MAINTAINED DURING AUTONOMY) Factor 3 MACHINE PARAMETERS ARE NOT PROPERLY SET

11 4M Method Establishment of standardized work NOT using standardized working routines could generate: The method must be standardized and followed correctly by the operator If the standardized work instruction does not exist, operators carry out their jobs in their own ways, resulting in the fluctuation of conditions, thus, change of quality. This eventually leads to reduced yields. 11

12 4M Man Human Error (H.E.) Human Error. The failure of a worker to perform an assigned task correctly. Difference between the expected result and produced result in a process that can be affected by human activity. 12

13 Man related issues 4M Man Human nature Knowledge Lack of knowledge Skills Overconfidence Immaturity Education and Training Man Bad habits due to past experiences Attention Health problems, fatigue, worries Excessive stress Loose mind Carelessness Absent mindlessness Misunderstanding, misjudgment, misoperation 13

14 4M Man Countermeasure against H.E. Human beings make mistakes however hard they are trained not to do so. Warning of not to make mistakes is relying on the unreliable human nature. In other words, leaving a room where people are liable to make mistakes and asking them not to do so does not make sense The thinking of reducing human mistakes and the one of eliminating them are two different things. The problem is the existence of a possibility of creating an error There is a limit for reducing human errors, we should find physical solutions to exclude human element of making mistakes. Make a system such that human errors cannot happen. 14

15 4M Material Supplier QUALITY Classify and prioritize suppliers Guarantee incoming material quality by proper inspection methodology For strategic suppliers move to a proper supplier process control. Suppliers deeply involved in design phase 15

16 The journey to zero defects IN FACTORY I operate equipment for zero defects I coach, educate and facilitate for zero defects I maintain equipment for zero defects Operator Quality Professional Maintenance I motivate and provide resources for zero defects Zero Defects Supervisor I ensure that employees are trained and systems are followed for zero defects Factory Director Manufacturing Manager I focus on driving system improvements for zero defects

17 3. QUALITY IN LOGISTIC WAREHOUSE & TRANSPORT General requirement Warehouse requirement Transport requirement

18 Quality in logistic General Requirement Quality Management system Management responsibility (quality & consumer safety) Document control Controls of record Internal audit Corrective & preventive action Management of Non conformance, Damage and Return Regulatory Compliance Incident Management Complaint handling Risk assessment & risk management

19 Key points in risk management Prerequisition program: Storage of Food, HPC, packaging materials, Ingredients (if applicable) and non-food chemicals must be done to prevent contamination. Hygienic facility must be maintained Access to the site must be controlled. A risk assessment must be conducted to identify a list of critical equipment that impacts quality and consumer safety. Documented procedures must be in place for isolation and disposition of damaged product Training record with defined frequency

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21 Quality in logistic WAREHOUSE REQUIREMENT Site security: ensures product safety and integrity Loading/Unloading: all incoming products must be inspected at the point of receipt for any non-conformance. Design & Storage: facility and its equipment Traceability: must be able to trace products from supplier to customer (tested annually) Quarantine & block products: must be under proper control Order picking: FEFO/FIFO principles Customer return: must monitored and recorded quality reasons Maintenance: facility and its equipment is maintained and minimise any risks to product quality Cleaning/Personal hygiene Pest control Damages & Waste

22 Quality in logistic Transport requirement Must be clean, free from odor and in a condition that enables ease of cleaning The container must be water tight CONTAINER REQUIREMENTS AREA MUSTS Free from water surface Floors must be dry and without condensation signs Container Interior Clean and free from any visible contamination (previous cargos) Free from any odor unpleasant and pleasant Free from damage and protrusions Doors Closing and Locking mechanism Hinges must be integral and free from excessive corrosion Seals must be in a good state of repair Must be in a good state of repair ad operate Drivers must conform to the site rules and policy

23 3. QUALITY IN LOGISTIC CUSTOMER Establish quality standards hand in hand with customers Proactively listen to customers/consumer through trade-visit, product on shelf inspection, consumers engagement center

24 - THANK YOU -