Golden Six

CII-Master Class

2nd Dec-2015, New Delhi

Harshad Pathak

Take Home messages the juice…..

Golden Six is

• Common sense (…Caution it is not always common)

• Simple tool to identify the themes /

patterns in food safety

• Preventive measure to drive Continuous

improvement

• Our senses are our tools

• Our wisdom is our skill

• To Fulfil our purpose

Nourishing families so they can flourish

and thrive

Agenda

• What are the “Golden Six”? – A simple way of looking at a plant’s overall food safety conditions

• How does the process work?

– It starts from the outside and moves in

• What are the key indicators?

– Red Flags and Out of Compliance Indicators

• Practical Implementation in factory

• Questions

….a bit of History Why was Golden Six created

• The “Golden Six” was created as a way to simplify the many requirements for a food

manufacturing facility

• The idea was to “boil down” requirements to the very basic expectations for food

plants

• This was done using feedback from

regulatory inspections, internal

inspections and CODEX requirements

• A “Golden Six” assessment can be done relatively quickly to provide an overall

view of a plant’s food safety conditions

What is Golden Six? Let’s keep it simple…

6 Basics of Food Safety to check out, more the Red Tags better Stop……….

Golden Six

Important Tip Are we seeing the same thing?

Get Calibrated, learn to connect the dots…

What should we look for? Devil is in the details…

Key Out of Compliance

Indicators…

Why do we hate

water?

• …Because Pathogens

loves them

• Single most

effective way

to avoid any

microbial

growth in

lines and

environment

• Any external

water coming

inside the

factory is

direct

contamination

of Pathogens

What’s wrong with pests?

• They bring in

Pathogens

• They

contaminate

our products

• Ethnic foods

issue

• Cereals are

prone to

insect

infestation

What does this

tell us?

• They bring in

Pathogens

• They

contaminate

our products

• Ethnic foods

issue

• Cereals are

prone to

insect

infestation

What should we look for? Devil is in the details…

Key Out of Compliance

Indicators…

Why do they

indicate?

• They carry

pathogens

through hands

• They carry

pathogens

through shoes

and materials

• Can

contaminate

with foreign

matter

• Allergen

contamination

What’s wrong with this?

• Foreign

material

contamination

• Microbiologic

al

contamination

• Breeding of

microbes

• Allergen

contamination

What does this

tell us?

• Foreign

material

contamination

• Pest entry

and

contamination

• Breeding of

microbes

• Allergen

contamination

How does that work?

Score Card Helps to determine a pattern

Theme could be a requirement or a specific

area

The Process of Golden Six How we use them in our facilities

Golden Six

How we have implemented…

Must do’s activities visuals… Compliance check to GMP & PPE’s

Daily Must Do’s trending

EHS Must do’s

Q&FS Must do’s

No observation = < 2 observations > 2 observations Days

Safety Goggle

17%

48% 53%

47%

74%

60%

10%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

Jun Jul Aug Sep Oct Nov Dec

Green Yellow Red

Ear

Plug 100% 100% 100% 100% 100% 100% 100%

0%

20%

40%

60%

80%

100%

120%

Jun Jul Aug Sep Oct Nov Dec

Green Yellow Red

Safety

Shoes

7%

55% 60%

80% 77%

47%

3% 0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

Jun Jul Aug Sep Oct Nov Dec

Green Yellow Red

Hair

net

43%

83%

100% 100% 100% 100% 100%

0%

20%

40%

60%

80%

100%

120%

Jun Jul Aug Sep Oct Nov Dec

Green Yellow Red

No

Jewelry 100% 100% 100% 97% 100% 100% 100%

0%

20%

40%

60%

80%

100%

120%

Jun Jul Aug Sep Oct Nov Dec

Green Yellow Red

No loose object above

waist

Till Date G6 trending The visual monitoring keep action live.

% of Green, Yellow and Red overall days period wise for 2015

G6 trending…… Measurement of every bucket for effective actions

Water control Pest control Sanitation & Housekeeping

Employee practices Overhead cleaning Condition of Bldg / equ

15% 9%

30%

19%

25%39%

46%

27%30%

33%22%

17%

3%

23%

21%19%

8%

19% 18%22%

63%

74%

67%

58%54%

42% 46%

54%52%

44%

0%

10%

20%

30%

40%

50%

60%

70%

80%

P1 P2 P3 P4 P5 P6 P7 P8 P9 P10

59%

57%

42%

65% 54%58%

54%58%

73%

67%

0%4%

6% 8%4% 3%

0% 0%3%

0%

41%

39%

52%

27%

43%

39%

46%42%

24%

33%

0%

10%

20%

30%

40%

50%

60%

70%

80%

P1 P2 P3 P4 P5 P6 P7 P8 P9 P10

7%

0%6%

19%14%

26%

12%15%

12%

22%19% 17%12%

23%

21%

6%

19%

4%9%

22%

74%

83%

82%

58%

64%68%

69%

81% 79%

56%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

P1 P2 P3 P4 P5 P6 P7 P8 P9 P10

33%

39%

61% 62%57%

52%

62%

54%

39%

56%

11% 13%12%

8%

14% 10%

8%12%

24%22%

56%

48%

27%31%

29%

39%

31%35%

36%

22%

0%

10%

20%

30%

40%

50%

60%

70%

P1 P2 P3 P4 P5 P6 P7 P8 P9 P10

74%

65% 73%81%

96%

90%

77%

85%

76% 78%

15%

0% 0%

12%

0%

6%19%

8% 9% 11%11%

35%

27%

8%

4%3% 4%

8%

15%11%

0%

20%

40%

60%

80%

100%

120%

P1 P2 P3 P4 P5 P6 P7 P8 P9 P10

7%

39%

42%23%

39%

58%62%

65%

58%

44%

7% 9%

0%

15%7% 6%

0% 0%3%

11%

85%

52%

58% 62%

54%

35%38%

35%39%

44%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

P1 P2 P3 P4 P5 P6 P7 P8 P9 P10

Period P10 Period P10 Period P10

STATUS (All) STATUS closed STATUS (Multiple Items)

Row Labels Count of Nature of finding Row Labels Count of Nature of finding Row Labels Count of Nature of finding

Condition of bldg /equip 86 Condition of bldg /equip 42 Condition of bldg /equip 44

GMP practices 60 GMP practices 37 GMP practices 23

Overhead food stream 16 Overhead food stream 8 Overhead food stream 8

Pest Control 6 Pest Control 5 Pest Control 1

Sanitation / Housekeeping 29 Sanitation / Housekeeping 22 Sanitation / Housekeeping 7

water control 12 water control 8 water control 4

Grand Total 209 Grand Total 122 Grand Total 87

Period P10 Period P10 Period P10

STATUS (All) STATUS closed STATUS Pending

Row Labels Count of Nature of finding Row Labels Count of Nature of finding Row Labels Count of Nature of finding

Ashok M 97 Ashok M 54 Ashok M 43

Nilesh A 9 Nilesh A 6 Nilesh A 3

Rupesh 7 Rupesh 7 Sangram 1

Sangram 1 Shyam 1 Shyam 3

Shyam 4 Rajesh K 11 (blank) 2

(blank) 2 Sandeep R. 1 Rajesh K 4

Rajesh K 15 Prashant K 1 Nitin N 1

Sandeep R. 1 Vijay G 7 Prashant K 5

Nitin N 1 Manish J. 1 Rupesh 1

Prashant K 6 Sandeep R 6 Manish J. 1

Vijay G 7 pramod w 6 Sandeep R 2

Rupesh 1 Rupesh s 3 Shilpika J 5

Manish J. 2 Rajesh/Vijay 4 pramod w 7

Sandeep R 8 Hemant 1 Rajesh k. 1

Shilpika J 5 Rajesh K/Vijay G 1 Rupesh s 1

pramod w 13 Rajesh 1 Rajesh/Vijay 1

Rajesh k. 1 Rupesh/Santosh 1 Jitendra K 1

Rupesh s 4 Sonavane B. 1 Amit/Rajesh K/Vijay G 1

Rajesh/Vijay 5 Rajes K 1 Rajes K 1

Jitendra K 1 Rajesh v 2 Bharat S 2

Amit/Rajesh K/Vijay G 1 Rupesh S/Santosh 3 Hemant S 1

Hemant 1 Santosh & Rajesh K 1 Grand Total 87

Rajesh K/Vijay G 1 Sandeep R & Santosh G 2

Rajesh 1 Grand Total 122

Rupesh/Santosh 1

Sonavane B. 1

Rajes K 2

Rajesh v 2

Rupesh S/Santosh 3

Bharat S 2

Santosh & Rajesh K 1

Sandeep R & Santosh G 2

Hemant S 1

Grand Total 209

G6 findings & Action Tracker Every action & accountability tracked..

58 % closure of the

points

G6 Visual Trend Visual trend to target specific area…

Finally it is Culture…… Do you know where are you on this maturity journey…

Golden Six Helps

Here

Questions?

Thank You for your attention