Golden lden Six CII CII-Mast Master er Class 2 nd nd Dec - PowerPoint PPT Presentation

Golden lden Six CII CII-Mast Master er Class 2 nd nd Dec Dec-2015 2015, , New Delhi hi Harshad shad Pathak ak

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 What’s wrong What does this water? water? with pests? tell us? • …Because • They bring in • They bring in Pathogens Pathogens Pathogens • They • They loves them • Single most contaminate contaminate effective way our products our products to avoid any • Ethnic foods • Ethnic foods microbial issue issue • Cereals are • Cereals are growth in lines and prone to prone to environment insect insect • Any external infestation infestation water coming inside the factory is direct contamination of Pathogens

What should we look for? Devil is in the details… Key Out of Compliance Indicators… Why do they What’s wrong What does this indicate? with this? tell us? • They carry • Foreign • Foreign pathogens material material through hands contamination contamination • They carry • Microbiologic • Pest entry pathogens al and through shoes contamination contamination • Breeding of • Breeding of and materials • Can microbes microbes contaminate • Allergen • Allergen with foreign contamination contamination matter • 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 lden 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 Safety Goggle Safety 90% 120% Ear Shoes 80% Plug 100% 100% 100% 100% 100% 100% 100% 100% 74% 70% 60% 60% 80% 48% 53% 50% 47% 60% 40% 30% 40% 20% 17% 20% 10% 10% 0% 0% Jun Jul Aug Sep Oct Nov Dec Jun Jul Aug Sep Oct Nov Dec Green Yellow Red Green Yellow Red Q&FS Must do’s No loose object above No 120% 90% 120% Hair waist Jewelry 80% 80% 77% net 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 97% 100% 100% 100% 70% 83% 80% 80% 60% 55% 60% 50% 60% 60% 47% 40% 43% 40% 40% 30% 20% 20% 20% 10% 7% 0% 0% 3% 0% Jun Jul Aug Sep Oct Nov Dec Jun Jul Aug Sep Oct Nov Dec Jun Jul Aug Sep Oct Nov Dec Green Yellow Red Green Yellow Red Green Yellow Red Days ys No observation = < 2 observations > 2 observations

Till Date G6 trending The visual monitoring keep action live. % of Gree een, , Yel ello low and d Red d overal erall days ys peri riod d wise se for or 2015 15

G6 trending…… Measurement of every bucket for effective actions Water ter contro ntrol Pest st cont ntrol ol Sanita nitatio ion & Hous useke keeping ping 70% 120% 90% 85% 80% 62% 60% 96% 100% 57% 56% 62% 56% 61% 70% 54% 90% 62% 52% 58% 65% 50% 85% 48% 62% 80% 60% 78% 52% 77% 58% 58% 76% 74% 54% 81% 40% 39% 39% 50% 39% 65% 73% 36% 60% 35% 44% 44% 33% 39% 40% 31% 31% 39% 39% 30% 38% 29% 27% 42% 35% 35% 23% 35% 24% 40% 30% 22% 22% 20% 27% 13% 11% 14% 20% 10% 12% 15% 15% 12% 20% 8% 19% 7% 6% 10% 15% 11% 8% 10% 6% 12% 9% 11% 11% 7% 7% 9% 4% 8% 8% 8% 11% 3% 4% 3% 0% 0% 0% 0% 0% 0% 0% 0% 0% P1 P2 P3 P4 P5 P6 P7 P8 P9 P10 P1 P2 P3 P4 P5 P6 P7 P8 P9 P10 P1 P2 P3 P4 P5 P6 P7 P8 P9 P10 Condit dition ion of Bldg / e equ Overhea erhead d cleani eaning ng Employ ployee e practices actices 80% 80% 90% 83% 74% 74% 73% 82% 81% 80% 70% 70% 79% 67% 67% 68% 59% 58% 64% 63% 70% 69% 60% 60% 54% 65% 58% 58% 58% 57% 54% 54% 54% 60% 52% 52% 50% 50% 56% 42% 43% 46% 46% 46% 44% 50% 41% 42% 40% 40% 42% 40% 39% 39% 39% 33% 33% 25% 30% 30% 30% 22% 23% 23% 27% 27% 30% 26% 30% 24% 22% 19% 20% 20% 17% 22% 22% 19% 19% 21% 18% 20% 17% 19% 12% 21% 15% 8% 19% 6% 12% 10% 10% 4% 4% 3% 19% 12% 7% 15% 10% 9% 9% 8% 14% 0% 6% 4% 3% 3% 6% 0% 0% 0% 0% 0% 0% 0% P1 P2 P3 P4 P5 P6 P7 P8 P9 P10 P1 P2 P3 P4 P5 P6 P7 P8 P9 P10 P1 P2 P3 P4 P5 P6 P7 P8 P9 P10

G6 findings & Action Tracker Every action & accountability Period P10 Period P10 Period P10 tracked.. 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 58 % closure ure of the Rajesh v 2 Rupesh S/Santosh 3 points Bharat S 2 Santosh & Rajesh K 1 Sandeep R & Santosh G 2 Hemant S 1 Grand Total 209

G6 Visual Trend Visual trend to target specific area…

Finally it is Culture…… Do you know where are you on this maturity journey… Golden lden Six x Helps lps Here re

Questions? estions? Thank You for your attention