STAGE 3 – HACCP PLANS

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1

Module 13 - Steps to Implement HACCP

Steps to Implement HACCP

Steps to Implement HACCP Cont'd.

Preliminary Step 1: Commitment of Senior Management

Preliminary Step 2: Choose a HACCP Coordinator

Roles of HACCP Coordinator

Roles of HACCP Coordinator cont’d…

Skills of a HACCP Coordinator

Preliminary Step 3: Prerequisite Program Maintenance

Phase II & III

Details of the first 5 Steps

Step 1: Assemble HACCP Team

1. Assemble HACCP Team

HACCP Team cont’d…

HACCP Team Meetings

Step 2: Describe the Product

Describe the Product

Form #1

Form #1, cont’d…

Additional Resources

Form #1 Example

Form #2

Form #2, cont’d…

Form #2 Example

Step 3: Identify Intended Use

Step 3: Identify Intended Use

Knowledge Check: Build Form #1

Step 4: Construct the Flow Diagram & Plant Schematic

Construct the Flow Diagram & Plant Schematic

Construct the Flow Diagram & Plant Schematic

Example of Form #3 - Flow Diagram

Additional Example of Form #3 Product name(s): Fresh Pork Sausage

Plant Schematic

Plant Schematic Examples of Form #4

Step 5: On-site Verification of Plant Schematic

On-site Verification of Schematic

Next steps: 7 HACCP Principles

7 HACCP Principles

Summary

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2

Module 14 - Identify Hazards

Identify Hazards

Step #6 – Identify Hazards

Step #6 - Identify Hazards

Who Should Identify Hazards?

Identifying Hazards

Identifying Hazards

Consider All Sources of Hazards

Identifying Hazards

Step #6 – Identify Hazards

Example of Updated Form #2

Ask Questions

Ask Questions

Step #6 – Identify Hazards

Example of updated Form #3

Examples of Process Hazards

Step #6 – Identify Hazards

Example of Updated Form #4

Verify Hazards

Hazard Control

Example of Form #5

Example of Form #5 continued

Example of Form #6

Example of Form #7

Step #6 – Identify Hazards

Knowledge Check: Hazard Match

Summary

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3

Module 15 - Determine CCPs and Other Controls

Determine CCPs and Other Controls - Page 1

Step #7 - CCPs and Other Control Measures

Step #7 - Critical Control Points

Process Controls

Process Controls

Determining CCPs & Risk Assessment

Critical Control Points

Critical Control Points

Critical Control Points

Further Examples of Common CCPs

CCP Decision Tree

CCP Decision Tree

Form #8

Form #8

How to Determine CCPs Using Form #8

How to Determine CCPs Using Form #8

How to Determine CCPs Using Form #8

Form #8 – Identification of Hazards & Prerequisite Question

Form #8 - Question #1

Form #8 - Question #1 Examples

Question #2

Form #8 - Question #2 Examples

Question #3

Form #8 - Question #3 Examples

Question #4

Form #8 - Question #4 Examples

Form 8 - Example with a Process Control

CCP Numbering

Form #8 – CCP Number example

Hazards Not Controlled by the Operator – Form #9

Hazards Not Controlled by the Operator – Form #9

Form 9 – Hazards Not Controlled by Operator

Once Control is Defined

Is it a CCP?

Summary

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4

Module 16 - Establish Critical Limits

Establish Critical Limits

Step #8. Establish Critical Limits

When to Set Critical Limits

Who Sets Critical Limits?

Establishing Critical Limits

Sources of Information

How to Set Critical Limits

Setting Critical Limits

Setting Critical Limits

Quantifiable (Objective) Limits

Qualified (Subjective) Limits

Knowledge Check: Critical Limit Match

Typical Critical Limits for Hazards

Options for Defining Limits

Examples of CCPs - Critical Limits

Examples of CCPs - Critical Limits

Examples of CCP - Critical Limits

Examples of CCPs - Critical Limits

Other Common CCPs with Defined Limits

HACCP Form #10

Form 10 – Examples

Form 10 Examples

Summary

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5

Module 17 - Establish Monitoring Procedures

Establish Monitoring Procedures

Step #9 - Monitoring

Importance of Monitoring

What is Monitored?

Monitoring Requirements

Monitoring Requirements

Monitoring “Musts”

Monitoring Procedures

Who Monitors?

Monitoring Personnel

Training

When Does Monitoring Take Place?

Where Does Monitoring Take Place?

2 Different Ways of Monitoring

2 Different Ways of Monitoring

Continuous Monitoring

Batch Monitoring

Form 10 - Example of Monitoring Column

Form #10 Example

Using Data from Monitoring

Creating Monitoring Records

Records Must

Monitoring Record Layout

Example of Record

Analyzing Example

Improved Example

Automated Systems

Automated Systems

Knowledge Check: What’s Wrong with This Form?

Summary

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6

Module 18 - Establish Deviation Procedures

Establish Deviation Procedures

Step #10 – Establishing Deviation Procedures

Definitions

Deviations

Written deviation program

Deviations

Deviation Procedures

Deviation Procedures

Food Safety Deviations

Other Deviations

Who defines deviation?

When to implement corrective actions?

What is done?

Where?

Records

What if no corrective action defined?

Corrective Actions

Product / Ingredients

People

Equipment

Area

Knowledge Check: Example of a Deviation

Preventative Measures

Preventative Measures

Example of Preventative Measure

Example of Form #10 Deviation Procedures Column

Form #10 Example

Form #10 Follow-up & Records

Closing the Loop

Summary

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7

Module 19 - Establish Verification Procedures

Establish Verification Procedures

Introduction to Verification

Verification

Validation

Verification & Validation

Why Verify?

Verification vs. Validation

FSEP Verification Requirements

Results of Verification

Ways to Verify

Record Verification

On-site Verification

Who Should Verify

When to Verify

Where & How to Verify Records

Where & How to Verify Records

Where & How to Verify On-site

Sample - Record Verification

Verification of Deviation

Verification of Deviation

If Deviation Not Addressed

If Deviation Not Addressed

Examples of Verification Procedures

Examples of Verification Procedures

Knowledge Check: Verification Crossword

Form 10 Example - Verification Column

Example of Form #10

Example of Form #10

Continual Improvement Loop

Regulatory Verification

Summary

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8

Module 20 - Record Keeping & System Maintenance

Record Keeping & System Maintenance

Step #12 - Records

Record - Keeping Systems

Importance of Records

Types of Records

Establish Record - Keeping Systems

Example of Form #10

Example of Form #10

Maintenance of HACCP systems

Changes That Trigger HACCP System Maintenance Procedures

Reassessment Requirements

Things to Cover Off

Reassessment Tracking

Reassessment of Prerequisites

Reassessment of HACCP Plans

Reassessment of HACCP Plans

Reassessment of HACCP Plans

Reassessment of Check Sheets

Verification

Knowledge Check: System Maintenance Match

Validation

Aspects of Validation

Examples of Documents to Support Validation

When to Conduct Maintenance/Reassessment/Validation Activities?

1. New Technologies - Examples

2. New Natural and RTE Foods - Considerations

3. New Combinations of Foods - Considerations

4. Changing Legislation - Considerations

5. New Information on Existing Issues

6. New Ways of Presenting Food to the Consumer

Auditing

Audits Initiated to:

Audit Objectives

Benefits of Auditing

Internal vs. External Auditing

Audit Classifications

Auditing

Auditing

3rd Party Audit results

Types of Audits

Types of Audits

Announced vs. Unannounced Audits

Audit Process Flow

Audit Considerations

Examples of Objective Evidence

Auditors

Audit Outcomes

FSEP Audits

HACCP SUMMARY

Summary

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