Jones Packaging Inc. HACCP Pilot Project

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Jones Packaging Inc.HACCPPilot Project

• London Guelph, Ontario
• 2006

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History

• Incorporated in 1920
• 4th generation privately held company
• Consistent history of profitability for over 85
  years
• 423 employees across 3 sites
• 80.6 growth in revenue since 1999

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London Facility

• Folding cartons, labels, shrink sleeves, folded
  leaflets/insert production and corporate office

• Construction completed in 1999

• Total area of 135,000 square feet

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Guelph Facility

• Total area of 120,000 square feet

• Folding carton and leaflet/insert production

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What about our Supplier Base?

• Suppliers are another generation away from the
  customer
• Most have not heard of HACCP
• Most have not seriously considered food safety
• Our job sell food safety to our suppliers
• Based on logic and understanding
• Purchasing decisions based on food safety
• Even when price still dictates.

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Vendor Certification

• HACCP being driven up the supply chain
• Vendor audit program
• Approved Vendor program
• Vendor audits are based on quality critical
  nature of the product and annual spend

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PAC HACCP Pilot

• Pilot Objectives, Requirements, and Expectations
• Objectives
• To assess the Draft Generic HACCP Standards and
  Workbook for the following
• Is it workable?
• Is it clear?
• Is it simple?
• Is it user friendly?
• Is it complete?
• Is it effective?
• Is it cost-efficient?
• Is it affordable?
• Does it integrate with other management
  processes?
• Is it well presented and formatted?

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• Is it workable?
• HACCP is a workable program. There is a mind set
  that must be adopted to set specific goals for
  the organization.
• Is it clear?
• HACCP is only a clear program, after investing
  considerable time to understand the various
  elements and risks. Once it takes shape in your
  mind, operating decisions based on real risk
  become second nature.

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• Is HACCP simple?
• No.it is not simple. Although the CFIA forms
  5, 6, 7 8 are very thorough, they also create a
  monstrous task of going over the same information
  very repetitively once for biological, once for
  physical and again for chemical hazards. The
  combined version of the 4 forms is far more
  workable. Caution, however, should be used
  before attempting to apply the combined form, to
  ensure the group has a SOLID understanding of
  each of the hazard assessment questions being
  asked. Considerable time can easily be wasted
  without adequate preparation by the group.
• The complexity is not to be underestimated.

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• Is it user friendly?
• I consider it user friendly with a lot of hard
  work attached. One element missing is the
  direction of a HACCP standard. A very good set
  of examples was provided through PAC and GFTC for
  the Pre-requisite Program and the HACCP Plan. We
  are systematically addressing those areas.
• Leadership from GFTC made the program achievable
  and helped keep things on track and in context
  for our business.

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• Is it complete?
• This HACCP format appears to be complete,
  addressing the primary risk areas with the
  Pre-Requisite program and systematic approach of
  the series of 10 forms.
• Is it effective?
• Properly applied, HACCP will improve a company by
  improving food safety practices.

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• Is it cost-efficient?
• Time will tell. If HACCP helps maintain existing
  business and brings new business to the table,
  then yes it is cost-efficient.
• There has been no identifiable reduction in
  spoilage costs for JPI because of the
  pre-existing controls.
• Is it affordable?
• It is very expensive to implement and maintain.
  Our customers will soon tell us if it is
  affordable.

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• Is it well presented and formatted?
• Yes, the program provided information of great
  value to the HACCP development team. Program
  facilitation through PAC and GFTC kept
  credibility and objectivity in the forefront.
• Onerous task to keep information flow organized.
• Volumes and volumes of development paper and
  electronic files
• Including 172 page workbook
• Currently at 55 pages of HACCP Program Documents
• Does it integrate with other management
  processes?
• The HACCP program can be seamlessly integrated
  into a formal quality system, as part of the
  system and not a bolt-on module. It should be
  integrated using existing information formats and
  control methods.

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To obtain specific feedback from the pilot
facilities on the following

• Feedback regarding care and maintenance of the
  standard
• We have a structure to apply to the packaging
  industry
• We need to draft a standard, using the knowledge
  gained from the pilot projects.
• Once written and validated, the wealth of
  information gathered during the workshops should
  be compiled into a compendium to support the
  Standard

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• Feed back regarding national and international
  applicability
• The HACCP program in its current form is a
  bountiful wealth of industry specific
  information. The value of this information in
  its current form would have limited appeal to an
  international market
• Development of a Packaging Standard, following a
  recognized protocol such CSA Directives and
  Guidelines Governing Standardization (or
  equivalent) will add credibility.
• Combine a Standard and a Compendium of
  applied practices for different scenarios and we
  will add considerable value and International
  appeal.

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• Are they still interested in implementing HACCP?
• I believe HACCP is a differentiator to build
  customer confidence and reduce risk. We will
  continue implementation to completion.
• Can it be duplicated in other company facilities?
• Our pilot spans 2 facilities. Careful
  implementation is recommended to prevent spending
  a lot of resource on very low risk issues.

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• Do customers find value in this program?
• With limited customer exposure to this program,
  one customer looked briefly at the combined form
  5-8, glanced at the CCPs and quickly moved on to
  the next issue, satisfied that we were diligent
  in our HACCP program.
• That would be a Yes.

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Orkin PCO/JPI HACCP Support Program

• Being developed through partnership with JPI
• biological monitoring program
• Water
• Contact surfaces
• Air grab samples
• Cost effective
• Tailored to the Packaging Industry
• Goal monitor with pest control program
• Package available for the industry when complete

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Questions
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