1

IMPROVEMENT OF INTEGRATED MANAGEMENT SYSTEMS:

IMPLEMENTATION OF ISO 22000 BASED FOOD SAFETY MANAGEMENT

Dr Zoltán ERDŐS Qualiment Ltd., Budapest

2007 PRAGUE PRAHA

51stEO

QCO

NGRE

SS

2

FUNDAMENTAL HYGIENE

(often without documented rules)

BASIC MEASURES, GMP / GHP, „ § ”

some additive regulations,

mostly incorporated to HACCP manual

CRITICAL CONTROL POINTS

HACCP REGULATION

CONTROL MEASURES INCLUDED IN HACCP

FOOD SAFETY IN PRAXIS traditional history

3

FUNDAMENTAL HYGIENE

(partialy documented rules - e.g. personal hygiene)

BASIC MEASURES, GMP / GHP D

ADDITIVE HYGIENIC and

FOOD SAFETY REGULATIONS ,

like SSOP’s, CUSTOMER REQUIREMENTS etc.

CRITICAL CONTROL POINTS

HACCP REGULATION

CONTROL MEASURES INCLUDED IN HACCP

FOOD SAFETY IN PRAXIS in progress

last 5 years

4

FUNDAMENTAL HYGIENE,

BEST KNOWLEDGE, GMP / GHP,

CODEX ALIMENTARIUS GL’s - PRP’s D

FOOD SAFETY REGULATIONS:

OPERATIONAL PRP’S

FOOD SAFETY CONTROL PROCEDURES

CRITICAL CONTROL POINTS

HACCP REGULATION

HACCP PLANS - CCP’s

CCP

op PRP

PRP

FOOD SAFETY IN PRAXIS ISO 22000 n o w

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HACCPISO

9001

GMP

GHP

ISO

9001

HA

CCP

GMP

GHP

ISO

9001HA

CCP

GMP

GHP

ISO

9001HA

CCPGHP

ISO

9001+

Integrated

management

system

Food safety management system

( IFS, BRC )

Quality management system

?

ISO

9001HA

CCP

GMP

GHP(PRP)

ISO

9001+

Food safety management system

( ISO 22000 )

op

PRP

ISO 22000 ISO 9001 ISO 14001

+ = REQUIREMENTS of

RETAILER CHAINS

Next member of food chain

process

Preceding

steps

a c t u a l s t e p

Related by-processesLinked processes

Preceding member

of food chain

personnel

EquipmentTools

environment

Next processes

Origin of rawmaterials

Following

steps

UtilizerConsumer

Final consumption

Preceding processes

analysis ofoperational steps

Step / No.:

Process:

Added components

= influence

8

FOOD SAFETY TEAM

PRODUCT DESCRIPTION

HACCP

VALIDATION OF MEASURES

PLANNING OF VERIFICATION

Planning and

production of safe

products

Process analysis

Hazard analysis

Risk assessment

a

b

c

d

op PRP CCP

PRP INTENDED USE

PROCESS FLOW DIAGRAM

HAZARDS, ACCEPTED .LEVELS

HAZARD & RISK ASSESSMENT

STEPS AND SAFETY MEASURES

SELECTION OF CONTROL MEASURES

HAZARD ANALYSIS

9

ENVIRONMENT,

RESOURCES,

BASIC HYGIENE

PRP op PRP CCP

OPERATION,

PROCESS

CONTROL,

TARGET

PARAMETERS

CRITICAL POINT,

process STEPS

CRITICAL

LIMITS

�

INTERVENTIONCONTROL

HAZARD ANALYSIS

10

DECISION TREE

ISO 22000

IDENT.OF HAZARDS,

ACCEPTED LEVELS

RISK ASSESSMENT:

PROBABILITIES

VALIDATION OF CONTROL

MEASURE COMBINATIONS

ELIMINATION IS

NECESSARY?

CONTROL IS

NECESSARY?

COMBINATION OF

CONTROL MEASURES

CATEGORIZATION

op PRP CCP

N CONTROL MEASURE NOT REQUIERED

Y

Y

N CONTROL MEASURE NOT REQUIERED

11

STEP FOR ELIMINATION

OF HAZARD ?

EXCEEDING

OCCURES ?

CONTROLLED BY

OTHER STEP ?

N

Y

N

Y

„ Y… N …Y … N ”

METHOD EXISTS?

Y

N

CCP

N

Y

no CCP

CCP

DECISION TREE

HACCP

HAZARD ANALYSIS

no CCP

12

PREVENTION IS

NECESSARY?

EXCEEDING

OCCURES ?

CONTROLLED BY

OTHER STEP ?

N

Y

N

Y

HAZARD ?

Y

N

CCP

N

Y

…or by OTHER

PROGRAM ? op PRP

Y

CCP

METHOD EXISTS?

STEP FOR ELIMINATION

OF HAZARD ?

DECISION TREE

HACCP

HAZARD ANALYSIS

„ Y… N …Y … N ”

„ Y… N …Y … Y ”

no CCP

no CCP

13

ENVIRONMENT

RESOURCES

BASIC HYGIENE

PRP op PRP CCP

OPERATION

PROCESS

CONTROLLED BY

PROCESS MANAGER

e.g. head of shift

(responsibility

by position)

documented by

weekly signing

of a record sheet

CRITICAL POINT

process STEPS

MONITERD BY

STEP OPERATOR

(nominated

responsibility)

documented by

daily signing

of a record cell

EXAMPLE

ONLY

nonconformities reported in a log-book

HAZARD ANALYSIS

14

STEP OPERATOR

PROCESS MANAGER

�

observations, nonconformities,

decisions, corerective actions

other measures ….

log-book

signatures: „OK” satus

(responsibility !)

X marks or notes: „incident” satus

(to report !)

15

Monica inspector

Veronica Q manager

Valeria production director

Plant manager

Head of shift

managing director

xxyxxyyxy

X ? = X !

? = ! ����

adding

new technology

or equipment

EXAMPLE

16

Monica inspector

Veronica Q manager

Valeria production director

Plant manager

Head of shift

managing director

xxyxxyyxy

X ? = X !

? = ! ����

Monitoring

Validation

monitoring verification validation implementation

Implementation

Verification

adding

new technology

or equipment

EXAMPLE

17

Monica inspector

Veronica Q manager

Valeria production director

Plant manager

Head of shift

managing director

xxyxxyyxy

X ? = X !

? = ! ����

continual use

EXAMPLE

18

Monica inspector

Veronica Q manager

Valeria production director

Plant manager

Head of shift

managing director

xxyxxyyxy

X ? = X !

? = ! ����

Monitoring

Management rewew

(Re)validation

implementation monitoring verification

Implementation

Verification

continual use

EXAMPLE

19

Monica inspector

Veronica Q manager

Valeria production director

Plant manager

Head of shift

managing director

xxyxxyyxy

X ? = X !

? = ! ����

Monitoring

Management rewew

(Re)validation

monitoring verification

Verification

continual use

EXAMPLE

planned frequency

ALIMIA Ltd. ISO 9001 + ISO 22000 basic documents

QUALITY MANUAL FOOD SAFETY MANUAL

PROCEDURES

FOOD SAFETY ?

RECORDS

QUALITY MANUAL FOOD SAFETY MANUAL

PROCEDURES

FOOD SAFETY

SUPPLEMENTS

RECORDS

ALIMIA Ltd. ISO 9001 + ISO 22000 basic documents

QUALITY MANUAL FOOD SAFETY MANUAL

PROCEDURES

FOOD SAFETY

SUPPLEMENTS

F.S. CONTROL DOCUMENTS

RECORDS

ALIMIA Ltd. ISO 9001 + ISO 22000 basic documents

QUALITY MANUAL FOOD SAFETY MANUAL

PROCEDURES

FOOD SAFETY

SUPPLEMENTS

F.S. CONTROL DOCUMENTS

RECORDS

ALIMIA Ltd. ISO 9001 + ISO 22000 basic documents

TOP MAMAGEMENT

TRADITIONAL MANAGEMENTFUNCTIONAL MANAGEMENT SYSTEMS

( BUSINESS, PRODUCTION, TECHNICAL,

MARKETING, SALES ETC. )

QUALITY FOOD SAFETY HACCP ENVIRONM..

QP– HP – EP –

PRODUCTION,

TECHNOLOGY

M ŰV. DOK

R E C O R D S

MARKETING

Company Statute

GENERAL PROCEDURES P-

REGULATIONS

MANUALS

FUNCTIONAL PROCEDURES (QP, ...)

INSTRUCTIONS, CODES, PROF.DOCUMENTS

TECHNOLOGICAL

TECHNICAL

PROD.DEVELOPMENT

PURCHASING

HUMAN RES.

OTHERS

SALES

INFORMATICS.

CONTROLLING

TQM

IMPROVEMENT

INTEGRATED MANAGEMENTSYSTEM

QUALITY HACCP

PLANS,

FOOD

ENVIRONMT

REGUL.HYGIENE

SSOP’S

SANITATION

( PRP )

25

CREATIVITYTHINKING,

EXECUTION

FREEDOM +

RESPONSIBILITY

PRESCRIPTIONS +

DIRECTION

BRAIN FUNCTIONS, ABILITIES

QUICK ,

„INTUITIVE”

DECISIONS

SENSORIC,

ABSTRACT,

INSPIRATIVE

FUNCTIONS

IMAGE -

PROCESSING

INTUITION,

EMOTIONS

EXPERIENCE

UNCONSCIOUS

(QUICK)

THINKING

LOGICS

MATHEMATICS

STEP BY STEP

THINKING

KNOWLEDGE

STRATEGY

„BUSINESS”

EGO

CONSCIOUS

DECISIONS

PLANING

EXACT

REALIZATION

MANAGING

FUNCTIONS:

EXECUTION

REALIZATION

FULFILMENT

TOOLS:

REGULATIONS

INSTRUCTIONS

MANAGING

FUNCTIONS:

PROBLEM-

SOLVING

TOOLS:

FUNCTIONS

RESPONSI-

BILITY

THANK YOU !