PepsiCo Kolkata Plant Food Safety & Quality Excellence Journey - - PowerPoint PPT Presentation

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PepsiCo Kolkata Plant

Food Safety & Quality Excellence Journey

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ISO 22K implemented. AIB Unannounced audit TPM Excellence Award HACCP Certification

2006 2007 2008 2005

Plant Startup OHSAS 18001 Certification

2013

ISO 14001 and AIB journey started TPM consistency award & CII National Food safety Award TPM Kick off

2009 2012 2014

+905 in AIB Unannounced audit

2004 2015

Kolkata Plant Journey

Center of Excellence (H&S

Kolkata Plant Journey

Journey Towards Excellence

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FSMS American Institution

• f Baking

(AIB)

HACCP 2006-2011 ISO 22 K 2012-2015 FSSC 22 K 2016 .. Onwards Announced GMP inspection Unannounced GMP inspection Quality Program QSHA standard implementation Quality System Health Audit

Food Safety system in PepsiCo

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A brief about AIB Inspection system

NEW SCORING MATRIX <700 – UNSATISFACTORY 700-910 – RECOGNITION OF ACCOMPLISHMENT (With no Unsatisfactory finding) 915-1000- RECOGNITION OF ACHIEVEMENT (With no serious finding)

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AIB GMP inspection – Announced to Unannounced

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Kolkata Manufacturing Excellence through TPM

Food safety Quality QM Pillar Approach

Integration of food safety and HACCP guidelines under QM - pillar. Circle Targets Identification of Q Component & Monitoring through JH

Standards

Focused Task forces

Plant Quality & Food safety KPIs

An engaged culture at plant developed through participation by all from each level… It’s plant’s way of life

Focused approach on Challenging food safety & Quality through QM Pillar approach

Expanding QA activities till distributor end: Latent defect control

More focus on food safety benchmarking

Supporting JH and E&T to develop process competent operators

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Circle audits Circle audits Circle audits Circle audits Monthly Review Action plan Practice Related

Infrastructure / System

Abnormalities

Corrective Action Plan Check Reoccurrence

Kaizen implementation Maintenance Prevention

Food Safety Monitoring Tools

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Major challenges

Sustenance of Each Day AIB Day

Training and awareness (Project and regular manpower)

Huge man movement inside the plant due to multiple projects

Biomethanation Canteen Expansion Sprinkler project Septic tank & PM expansion project

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No Unsatisfactory Condition Due To Pest

• No pest related consumer complaint received till date

Regular Spray At Plant Exterior By PCI Operators

Bird netting done for all RM /Agro / FG docks

Sample Pest Control Spray Log Sheet

Daily Rodabox Monitoring Sheet

Daily Pest-o-flash monitoring sheet

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After

Second Line Of Defense Prepared to restrict bird and pest During Loading Unloading Despatch shutter open and entry for bird and other pest

Before Before After

Zero bird entry incident

No Unsatisfactory Condition Due To Pest

Door Discipline, Receiving Inspection & Cleaning Of Pallets On Daily Basis

No Unsatisfactory Condition Due To Pest

Closed 40 no

• f potential
• penings for

pest entry

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Daily Tool Box Talk at all project sites

Project Display Boards and physical separation CCTV cameras & shoe cleaners at process entry

Awareness against sources of contamination

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Plant Engagement program on Food safety

Teacher –student model Food safety related OPLs Slogans & Posters

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Food Safety PEP Talk , OPL Display & Communication

Food Safety PEP Talk With Operatives During Shift Communication Food Safety OPL Display At Shop Floor. Food Safety OPL Docket Food Safety PEP Talk With Casuals During Plant Entry Classroom Training For Management Training Validation

Sample Validation Sheet

• 1. Circle Audit
• 2. Internal audit
• 3. External audit
• 4. Other findings

Monthly review Gap analysis Action plan Class room training / on job training Communicatio n/ Pep talk/ OPL/ Displays Validation by validation team

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Plat’s Egageet progra o Food Safety week & Global handwashing day

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QM Pillar & E&T Pillar _ Collaborative drive - OLC Developing & Uploading Quality & Food safety Modules in OLC ( ON Line Learning Centre ) – Each One Teach One

Quality dockets available In online learning center

AIB training ppt HLE ppt Procedure for potato receiving Store Frito-Lay way HACCP module Storage procedure

Quality videos available In online learning center

Agro sampling Packaging & palletizing Personnel hygiene Trim & pair station

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Daily Self Inspection Review – Each day AIB Day

Abnormality List Was In Decreasing Tread Within Very Short Time

Before After

Daily Review With Management Team During Management Wall Meeting

Per Day AIB Abnormalities,

80 45 20 10 5 25 45 65 85 Ave/Day( WK-1) Ave/Day( WK-2) Ave/Day( WK-3) Ave/Day( WK-4)

No of AIB abnormalities

Q PT

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Engagement program- KPL – QM an integral part

Kolkata Premier League – Plnat’s biggest engagement program – QM pillar is an integral part of this program – It is Learning through Fun , powered by Team Kolkata

Demo on Q- Defect

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Plat’s Kaize Coferece – observes Quality improvement & Food Safety related Kaizens – R&R

Pratiyogita E kaizen Q1 2015

Sharing kaizen s related to Safety , Quality & Productivity

KK – Pratiyogita E kaizen Q2 2015

Sharing kaizen s related to Safety , Quality & Productivity

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Maintenance Kiosk – Tag Management of Food safety related issues is included

Posting of Tags prior to sanitation program Categorization of Red Tag & White tag Food safety Tags – priority A and Tech- support allocated to sort out issues Post Boilout Compliance of Red & White tags are monitored

QM & PM Pillar Intervention

Communication during sanitation day

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First plant to clear Unannounced audit

Highest ever score of +905 in 2015 among all food plants in India

500 550 600 650 700 750 800 850 900 950 1000 2011 2012 2014 2015

815 760 870 905

AIB Score

AIB Score

Result summary

Highest Score in Unannounced audit

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