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FQSSMS Summer 2004 Food Quality Safety Security Management System


Summer 2004 Food Quality Safety Security Management System Jim Gallagher, Ted Lippert, Roger Newhouse, Dennis Rogers, Troy Shrider Project Focus There are many ... – PowerPoint PPT presentation

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Title: FQSSMS Summer 2004 Food Quality Safety Security Management System

FQSSMS Summer 2004Food Quality Safety Security
Management System
Phase II
  • Jim Gallagher, Ted Lippert,
  • Roger Newhouse, Dennis Rogers,
  • Troy Shrider

Project Focus
  • There are many diverse Safety and Quality
    Standards which the food industry is barraged by
    while trying to conduct business. At this time
    there is no one place where a company in the food
    business can go to and compare the differences
    and likes between the different standards.

Project Objectives
  • Objective 1 Complete five toolkit assignments,
    assessing four SDAs in each toolkit against
    comparable elements of a (real or simulated)
    organizational quality system, or modifying tools
    to enhance organizational quality system,
    presenting findings, recommendations as phase

Project Objectives
  • Objective 2 Develop team portfolio incorporating
    the evolution of the 3 Regular Critique
    Assessments (RCAs), 20 required Standard
    Dedicated Audits (SDAs), and 20 optional
    Standard Dedicated Audits (SDAs) found in Tools
    29 33 and 36 - 40.

Project Objectives
  • Objective 3 Replace Compiler Responsibilities in
    tables with FACR (Findings, Analysis,
    Conclusions, Recommendations)

Project Objectives
  • Objective 4 Complete Table Cross
  • ISO 9001
  • GFSI (General Food Safety Initiative)
  • NFPA/SAFE (National Food Processors Association/
    Supplier Audits for Food Excellence)
  • HACCP (Hazard Analysis Critical Control Point)
  • CODEX (European Food Safety Standard)
  • GMP
  • SDA/Tools (Industrial Technologists Standard
    Dedicated Audits)

Project Objectives
  • Objective 5 Redesign, and complete several
    examples of an OPCP and FMEA for Food Industry
    using Hirzels process as example

  • Research data and process insight were gathered
    by working on toolkits 29-33 and 36-40 from The
    Industrial Technologists Toolkit for Technology
    Management (Dr. John Sinn, 2003).
  • On-line meetings were held bi-weekly to discuss
    and evaluate the progress of the project, with
    guidance from Dr. Sinn.
  • Course Discussion boards and e-mails were used to
  • The team brainstormed potential projects and

Project Organization Chart
Project Organization Chart
Tool kit 29 Summary
  • ISO and QS are introduced, with reference to
    Baldrige criteria.
  • ISO 9000 is reviewed and requirements and QS
    needs discussed.
  • Item 4 in QS9001-2002 addresses the development
    of a Quality Management System.
  • ISO 9001 is streamlined with TS 16949 2002.
  • The Environmental 14000 standard has six elements
  • The need and benefits of Auditing Quality Systems
    is reviewed.
  • Kaizen, six sigma and lean relationships are
    briefly reviewed.

Tool kit 30 Summary
  • Focus on Change Improvement SOPs, Kaizen,
    Internal and External Customers
  • Defining the Meeting and Culture
  • how to conduct productive project meetings
  • Problem Solving
  • Cause and Effect
  • Brainstorming
  • Team Behaviors
  • Forming
  • Storming
  • Norming
  • Performing

Tool kit 31 Summary
  • Problem solving, documentation, lean foundations,
    quality systems
  • Corrective actions, 8-D approach
  • Ongoing process control plan (OPCP) and standard
    operating procedures
  • Time study, work methods and work sampling
  • Operation, process, capacity determination
  • Plant layout and flow diagramming
  • Man-machine analysis--common sense approach
  • Failure mode and effects analysis (FMEA)
  • Kaizen, costs and planning for lean

Tool kit 32 Summary
  • Statistical principles
  • Quality system standards
  • Six sigma
  • Charts, graphs
  • Attribute charting systems
  • P charts
  • Attributes, checklists and charting
  • SPC, X-bar and variable charting
  • Cp and Cpk
  • Quality characteristic foundations, changing
  • Metrology and Inspection

Tool kit 33 Summary
  • Basic requirements for E-commerce, information
    and service
  • Information technology, automated electronic
    push Traditional services
  • Information shared for work cells, analysis and
    control, flexible services
  • Types of maintenance service underpinnings for
    waste reduction
  • Total productive maintenance for lean
  • Selected troubleshooting fundamentals
  • Safety services

Tool kit 36 Summary
  • ISO and QS Introduced
  • Process and level classifications, tiers
  • Launch systems for quality
  • Fundamental definitions, classifications, phases
  • The Service Function
  • Service as upstream function, value added
  • Understanding customers and suppliers
  • Kaizen
  • Serving External Customers

Tool kit 37 Summary
  • Teams, Kaizen, problem solving
  • Materials
  • Classification
  • Considerations
  • Characteristics
  • Material and process testing
  • Technological Processes
  • Enhanced Design,
  • Creativity and The Five Why's
  • Innovation and Management strategies
  • Implementing Innovation and Change
  • Applied Technical Research

Tool kit 38 Summary
  • Launch data and documentation systems
    production qualification
  • Feasibility Analysis production capability
  • Sampling and Inspection Procedures
  • Short Run Systems mini run, pre-control,

Tool kit 38 Summary
  • Quality Characteristics statistical indexes
  • Engineering Design Change Documentation
  • PSDOE (Preliminary Design of Experiment)
  • Reliability Design FMEA
  • PPV (Production Part Verification)
  • Certificate of Compliance

Tool kit 39 Summary
  • New product development, life cycle
  • DOE and FEA
  • Separate and in-tandem
  • Advanced technological problem solving
  • DOE Taguchi style
  • Reliability
  • issues and relationships to robust design
  • Selected reliability measures
  • Finite Element Analysis (FEA)
  • General FEA procedures
  • Garage Door Bracket Case Study
  • Integrated DOE and FEA systems
  • Applying DOE methods to FEA

Tool kit 40 Summary
  • Automation, computer integration and the
    electronic push
  • CAD-CAM systems plus
  • Data acquisition for quality improvement
  • Concurrent design and geometric dimensioning
  • Local area networks
  • Group technology, work cells and flexibility
  • Computer analysis and control
  • Effects of computer integration on production

  • Findings
  • ISO 15161 already exist as pertaining to the food
    industry and HACCP
  • There are numerous codes or standards by which
    the world wants to guarantee the integrity of
    its food supply. All have the same basic goal of
    safety and security when it comes to microbial,
    disease or foreign objects in the food.
  • Team has found project focus
  • New documents uncovered for team to study Global
    Food Safety Initiative and add to our
    cross-reference table.
  • We have standards covering the safety side, need
    standards to ensure product quality
  • Evaluation of tools and their applicability to
    the FQSSMS project seems to be emerging. The
    team has great momentum, experience, enthusiasm
    and curiosity. A lot of work has been
    accomplished in a short period of time, on many
    levels. The challenge of on-line communication,
    in a very short period of time, has been met with
    success. Final objective is in sight, and Phase
    II should be solid.
  • Two weeks left in class, time is a major issue.

  • Findings continued
  • http//www.statease.com/pubs/foodtech.pdf
  • The teams focus is on Phase ll and cleaning up
    Phase l.
  • Tool 32 and 39 add additional value to the FQSSMS
    by giving us the ability to uses variable and
    attribute data to measure process capabilities.
    Reliability data is a little beyond the scope of
    the project at this time but will be a powerful
    tool once the system matures.
  • Goals are now clear, a cross reference table
    relating several quality systems to food service
    industry and an FMEA OPCP that the industry can
  • There has been less focus on what Hirzel does,
    and increased focus on the quality issues in food
    processing. This has been a positive shift,
    allowing researchers to develop a core
    understanding of the regulatory compliance issues
    with regard to quality.
  • As long as the team communicates and posts on a
    timely manner we should be able to finish the
    final projects with strong presentations.
  • The team focus is finally clear.

  • Analysis
  • ISO 15161 unavailable to team at this time.
  • The common elements of these standards can be
    assessed and presented in a tabular format to
    allow food industries to more readily assess
    their compliance on a global scale.
  • Research is needed.
  • Still need a copy of ISO 15161.ISO standard has
    been proven over time to increase product
    quality. Not all sections apply to food industry
  • It will be better judged after Sunday and Monday
    night chats, spooling into table, last tools, and
    final portfolio. Understandably, a lot on the
    plate for the team right now.
  • Most of time is being spent doing forms and

  • Analysis continued
  • This is an article aimed at using DOE software in
    the food industry.
  • The quality of our final compilation will depend
    on our ability to communicate any needed
    improvements and to post our work in a consistent
  • Team is becoming more focused and communication
    has improved. The table is starting to gel.
  • The communication of the team has been
    outstanding the last two weeks. One more week
    and the completed project will exceed initial
    expectations from such a short time frame.
  • Lack of intimate knowledge with Hirzels
    operation results in application of tools on
    broader food production industry issues.
  • Communication is the key.
  • Troy and Dennis are working on a side project,
    which should be beneficial to team.

  • Conclusions
  • Since this integration of ISO and HACCP has
    already been done, then team needs to take
    another look at the project scope.
  • All global standards have the same basic goal.
  • Research will need to be done by all on team to
    accomplish task
  • Since the whole team is active now work can be
    divided up into researching these standards.
  • ISO 9002 (at least portions) need incorporated
    into the technical flowchart and quality system
    at Hirzel.
  • Solid team growth, communication, and progress on
    objectives. Need to finish even stronger.
  • If completion of table is to be done- we must
    start now.

  • Conclusions continued
  • Design Expert is the software specifically
    critiqued in this article. This DOE software is
    aimed at the food industry and is usable by
    someone with moderate experience with design of
  • We have been working well as a team and should
    continue to improve.
  • The original goal of defining the table is
    achievable. I also think we can stretch the QOS
    by the incorporation of the FMEA and control
  • Team summer needs just a little more effort to
    complete our goal.
  • This team has set the bar extremely high for
    future groups. The amount of work produced in a
    short period of time is impressive in its
    research and scope of application to the food
  • We still have quite a bit of work to do.
  • Once everything is put together information will
    be useful.

  • Recommendations
  • Obtain copy of ISO 15161 for teams review.
  • The team should make its best attempt to
    identify all of the global standards.
  • Obtain copies of standards and get to studying
  • Have a chat to decide how to divide up the work
    and continue on project off cross-reference
  • Review the ISO standard and determine which
    sections are most beneficial to the food
  • Will wait for Sun/Mon chat and brainstorming to

  • Recommendations continued
  • Decide on overall format and assign work for
    everyone to complete table.
  • Certainly something that someone at Hirzel should
    be aware of.
  • Continue moving forward and keep focused.
  • Continue with additional chats and formulation of
    FMEA and control plan.
  • Communicate, communicate, communicate
  • Continue to focus on the cross-reference table,
    providing yet another foundation for future
    groups to build on.
  • Continue to work hard in this last week.
  • Finish strong and plan and organize well.

  • Findings  
  • Interesting to see three different approaches to
    TPPMA, all equally valid. Its a little
    difficult to come to substantial conclusions this
    early, but the lack of 40 of the teams input is
    definitely a disappointment.
  • UNIDO United Nations Industrial Development
  • Project focus and team membership problems
  • With Jim being sick the team got behind. Also
    Troy just got back from vacation and Dennis
    started so team a little in disarray.
  • Strong team players. Everyone brings something
    to the table. Given a normal 4 month semester,
    this team could accomplish amazing things. Good
  • The team is now at a point where all are engaged
    fully and contributing.

  • Findings continued  
  • The whole team suffers when all are not able to
    contribute evenly.
  • We work together well as a team but we need to
    stay on track and focus on the same objectives.
  • Team is doing better job meeting deadlines and
    holding each other accountable. Team is also
    communicating more frequently as seen by several
    chat sessions and thread discussions. I feel
    that the last tools and Phase II of this project
    are going to gel and expectations will be
  • Team initially had about 50 participation.
  • The team is has learned to work together well and
    if all participate then the last portion of this
    class should go well.
  • Everyone worked well for tool 32/39.

  • Analysis  
  • Rankings appear to be similar in Ted and Rogers
    grading. My opinion is that Roger may be most
    on-track with his evaluation. Although were
    getting started, we still are not hitting our
    marks as a team. Im guessing hes being
    patient.for now.
  • This organizations websites offers links and
    information on the CODEX food safety and quality
  • Chat sessions clearing things up.
  • Based on the ratings parts of teams are doing
    well. Considering the chat on Wednesday July
    14th everyone is starting to get involved well.
    Thus ratings for all members should begin to
    equal out.
  • Feels like the start of the actual table
    (w/exception of Teds format in Excel) is a
    little late.
  • Dennis and Troy have both done a good job at
    putting team needs first (31-38) and themselves

  • Analysis continued  
  • The analogy of a chain, while overused, is still
    the best. All links must hold their share or the
    team will fail.
  • Team focus and timing are key elements at this
  • Everyone seems to be trying to step up the level
    of communication. All seem to have a sense of
    urgency with timing as the semester is about to
    end. I also believe that all team members now
    believe in the class format and tool processes.
    I for one was skeptical at first. But with the
    growth of the team and the project in just a few
    short weeks I am a believer.
  • This was due to sickness, late enrollments and
    workloads (both academic and professional).
  • As long as we continue to communicate, the
    objectives of these final projects should be met.
  • Team finally got in the groove and everyone
    contributed their part.

  • Conclusions  
  • (Speaking only of myself) Starting with the next
    tool/s submissions, the TPPMA will be approached
    with fewer leniencies.
  • This site is well presented and offers links to
    the CODEX site, the full text of the standards
    are available there.
  • As relationships build among team members unity
    to get job done is growing.
  • Team needs to continue on with project even when
    all members do not make deadlines.
  • Cross-reference table must be main priority
    through this weekend.
  • Team can really start working together now but
    how much time is left?

  • Conclusions continued  
  • It became apparent that the team would not be
    able to complete all six sets of tools.
  • There is little time left in the class but if the
    team can pull together we still can make these
    projects happen.
  • To exceed the expectations of Phase II, we must
    communicate even more.
  • People got healthier, dropped some other classes,
  • Each of the prior projects has become
    progressively better and the last one should
    continue along this path.
  • When team gets to know each other and trust each
    other to get work done things go better.

  • Recommendations
  • All that I would submit as a recommendation would
    be the obvious. Put some thought into the TPPMA,
    honestly express your impressions of the teams
    players, and take a look at what your teammates
    are saying in theirs. I think that the TPPMA is
    the glue of the team in a lot of ways.
  • The team should consider using this website as a
    reference source and jump off place
  • Keep chatting and communicating and everyone keep
    working hard to get postings in on time to stay
  • At chat on Sunday night we need to really close
    in on the general direction and who needs to do
  • Have the cross-reference table drafted for
    completion by Wednesday p.m. at the latest.
  • Focus on objectives!!

  • Recommendations continued
  • The last tool set (34/41) will be dropped from
    the course requirements.
  • Because of the limited amount of time left in the
    class we have to focus on communicating and
    planning to move ahead as fast and steady as
  • Communicate through e-mail or threads and chat
    nightly, even if only a few participate. Make
    sure to notify others that a chat has taken place
    so they can review the chat and keep up to speed.
  • This is good to keep in mind when accepting
    assignments, if youre in that position, not to
    overstretch yourself. This team was able to
    survive and even prosper because a core group of
    people were able to push through the lean times,
    allowing the others to join in and give above
    100 in the homestretch.
  • The team should not loose focus on these last
  • Keep same teams together in future if at all

  • Findings 
  • Through the courseware content the ISO elements
    were defined and explained briefly. Every good
    company will have an organized Quality system
    that follows these elements .It starts at the top
    with management commitments. The project focus is
    currently to find a way to integrate ISO elements
    into HACCP and the GMS. During some research by
    Roger Newhouse he found that the ISO and HACCP
    standards for food industry have already been
    integrated via ISO 15161.
  • Website for the Food and Agriculture Organization
    of the United Nations.
  • Team organization and meeting planning are
    important for any organization including our
  • Many quality tools are available to use for
    continuous improvement and new product launch.
  • There are many methods that a company can use to
    regulate the quality of a product
  • Statistical Process Control is used through out
    the quality field.
  • http//www.nal.usda.gov/foodborne.index/html

  • Findings 
  • The use of FEA is a valuable tool to produce
    quality cost effective products.
  • Tool 32/39 is the best tools within the tool set
    to date. They easily provide examples of how
    improvement can be obtained through data
    manipulation and collection. The tool does a
    very good job of showing how attribute data can
    be used. Attribute data is often overlooked in
    todays industries.
  • National Alliance for Food Safety and Security
  • Automation can improve both the speed and
    accuracy of certain processes.
  • New technology is out there to benefit a quality
  • Obviously an innovative approach, challenging
    manufacturing paradigms. Thinking out of the
    box, utilizing modern technology. Almost beating
    the consumer to the punch with regard to DEMAND.
  • Tools could relate safety in terms of internet
    security better. From reading the web article,
    attack by hackers is much higher than what most
    people think.

  • Analysis 
  • Management commitment is where Quality has to
    start Especially in any type of a launch. It
    also appears there is material available relating
    the ISO standard to the food industry
  • Very well structured and comprehensive website.
  • The service sector has the same needs for
    communication as the manufacturing industry.
  • Many involve sampling and or short-runs.
  • A company needs to use these tools.
  • ISO requires a documentation system such as this.
  • Wonderful site for exploring the world of Food
    Safety and Security
  • FEA is a good tool to compare various design
    while DOE is important to develop physical
    testing methods to determine true capabilities
    that a product has.
  • In less robust and infant quality systems,
    attribute data can be an easy way to monitor
    capability and drive improvements.

  • Analysis continued 
  • Universities participating in this alliance
    Auburn University, Iowa State University , Kansas
    State University , Michigan State University ,
    Mississippi State University , North Carolina
    State University , North Dakota State University
    , Purdue University , Texas AM University ,
    University of Arkansas , University of
    California-Davis , University of Florida ,
    University of Georgia , University of Idaho
    University of Illinois , University of Tennessee
    , University of Wisconsin , Virginia Tech
    University , Washington State University
  • While robotics and automation are often
    intelligent methods of manufacturing, they are
    not always the best route to go.
  • Is Hirzel using new technology like The CDS and
    do they have a TPM team or group?
  • There is a brief case study included at the end
    of the article. Team approach, maximize
    diversity of resources.
  • With the push toward paperless work, the risk of
    attack will continue to increase. According to
    the web article, most viruses attack weakness in
    Windows operating frames.

  • Conclusions 
  • Is the ISO 15161 standard workable or can we
    improve on it?
  • This is a good reference site for our team, it
    includes links to Codex and HACCP information.
  • Team FQSSMS is basically working as a service
    provider and in such need to refine our
    communications skills.
  • Working in teams is the best way to approach
    these tools.
  • The problem solving and improvement tools that we
    have covered are necessary to produce quality
  • Need to be sure this is included in other Quality
    mandates for the food industry.
  • Multitude of links to tons of HACCP online

  • Conclusions continued 
  • The use of FEA and DOE can help a company produce
    products that meet their customers needs.
  • A food service QOS should first work with what
    they have. That is usually minimal variable
    data, thus attribute data can provide a means to
    drive improvements with minimal investment.
  • Where is Bowling Green State University?
  • There will be many new automated processes to
    come in the future.
  • Every company should use new software and have
    TPM and safety work together to improve a quality
  • This is a very interesting concept that I had
    never heard of. I am familiar with Kan Ban,
    linked cell, and JIT.
  • Security of web based system has to be a top

  • Recommendations 
  • Have the group review the ISO 15161 standard and
    see what we can do. Maybe make a cross-reference
    sheet to examine all parts of ISO 15161 and
    HACCP. We need to research this more and chat
    about it.
  • Team members should review this site. 
  • As we problem solve use the 5-whys and staying in
    good communication about any topics we research
    with relevance to our project
  • Our team needs to communicate more to each other
    and use the planning techniques.
  • As a group we can learn to use these methods to
    create better quality standards.
  • Review GMP, HACCP, and GFSI.
  • All involved in HACCP need to have this site

  • Recommendations continued 
  • As these tools become more developed companies
    from all industries should be able to use the
    results to help further improve their products.
  • The tool needs further in depth detail on the
    six-sigma process. All ingredients are there.
    The tool also can be enhanced by adding a
    different format to the formulas, PDF file or
    scanned test book copies. Some of the formulas
    are confusing the way they are presented.
  • That BGSU look into joining this organization.
  • A company should look at new automation
    processes, but use these methods only when
  • Implement new software and TPM if not already
  • Does not apply well to food production/canning.
  • Update virus protection daily. Check for Windows
    updates on a daily basis also. Provide
    contingency plans in case of intrusion.
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