Managing Your Supply Chain for Food Safety in a Global Environment

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Managing Your Supply Chain for Food Safety in a
Global Environment

• Dane Bernard
• Keystone Foods

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Background

• Food companies must rely on multiple companies
  and Countries for food ingredients and packaging.
• Items can be manufactured in all parts of the
  world.
• Expectations placed upon suppliers is the
  foundation for food safety and quality.
• tartartrace.xls

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Expectation Areas

• Animal Welfare (if applicable)
• Biosecurity/Food Defense
• BSE Firewalls (if applicable)
• Residue Control
• Sanitation
• Pest Control
• Good Manufacturing Practices / Good Agricultural
  Practices Practices
• HACCP
• Foreign Material Control

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Expectation Areas

• Product Withdrawal
• Hold Procedures
• Product Storage
• Load Security
• Lot Identification
• Lot Control
• Traceability
• Laboratory Support (if applicable)
• Laboratory Testing Capabilities (if applicable).

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Animal Welfare

• Requirements specific for each species
• Safe and responsible animal treatments
• Accountability
• Auditable to acceptable standards
• Verified by all levels
• Internal audits 
• Second and third party audits
• Corrective actions
• Increasing use of Video Monitoring

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Sanitation

• Written Sanitation Standard Operating Procedures
  (SSOPs)
• Clearly defined responsibilities
• Assessment of effectiveness
• Preoperational visual inspection
• Equipment swabbing with tracking and trending
• Corrective action plans
• Use of appropriate sanitary design

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Foreign Material Control

• A systematic approach that considers sources of
  FM from
• People
• Place
• Product
• Prefer
• active audits
• Risk Ranking Using Failure Mode Effects Analysis
  framework to prioritize
• Tracking and follow through

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Eliminating a High Risk RPN

• This Batching combo hoist has Nylon guards which
  contaminate product due to the scraping of metal
  combos against the Nylon. These are not required
  as all suppliers use cardboard combos

RPN 140
RPN 0
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Thermometer Control

• In the facility there are many thermometers used
  and constantly make contact with product. These
  thermometer holding areas have been installed in
  areas where they are used.
• If the thermometer is not in its designated
  location, it is in use

RPN 432
RPN 120
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Load Security

• Keystone policy is that all loads must arrive
  with acceptable seal applied at departure point
  or trackable history of seal that is in place
  upon arrival.
• Cable or bolt seals are required on all access
  doors
• For less than truck load shipments, security must
  be applied at case and or pallet level.

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Traceability

• One up, one down is the minimum expectation
• Questions remain about extent of uniformity that
  will be needed on product and ingredient coding
  systems to be able to be more proactive on
  addressing food safety issues.

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Approval Process

• Basic understanding of the suppliers
  capabilities.
• Outlining our expectations.
• First or Third party assessment of conformance to
  expectations. Poultrysupplieraudit.docx
• Probationary approval.
• Limited purchases until a baseline can be
  established linking supplier performance with
  conformance.
• Active purchasing.
• Name placed on the Approved Supplier List (ASL).

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Approved Supply List (ASL)

• Specific locations which a Keystone facility can
  purchase items.
• Contains the latest history of a supplier.
• Annual audit results.
• Contact information.
• Non conformance results.
• Names of plants which have been delisted.
• ASL is a living document and should always be
  current.

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Supplier Verification

• Prioritize suppliers
• Pre-ASL audit compliance.
• Initial load(s) testing (if applicable).
• Normal monitoring schemes in place.
• Product dependent
• Time
• Type of monitoring
• Annual Audit
• Third Party Audit
• Keystone Audit

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Meeting Expectations

• Non Conformance expectations must be established.
• Differing levels of actions
• Minor infractions corrective actions
• Major infractions corrective actions and
  possible follow up
• Critical infractions suspension of supply
• Trending of data may indicate suspension of
  supply without a critical defect failure.
• Micro trends?
• Foreign material trends?

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Communication

• Constant feedback is a MUST! by Whom?
• Helps keep your expectations up to date.
• The goal is to have confidence and consistency in
  the products you receive.
• One Tip Partner with purchasing! Conduct
  frequent program reviews.

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Summary

• Be selective look for value not just price
• Clear expectations then verify
• Maintain and enhance the program
• Keep it simple
• Start with risk ranked suppliers and limited
  scope of expectations
• Elaborate on expectations
• Verify conformance with audits and appropriate
  testing/observations
• Id rather be here than shoveling snow in US!

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Summary