Quality management systems for the food industry : a guide to ISO 9001/2

203 Pages·1997·17.444 MB·English

by  Andrew Bolton

Quality Management
Systems for the Food
Industry
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QualityManagement Systemsfor the Food Industry
is a companion volume to Chapman & Hall's
Practical Approaches to Food Control and Food
Quality Series
Series editor: Keith G. Anderson
1 HACCP
Apractical approach
S. Mortimore andC. Wallace
2 CrisisManagementinthe Food and Drinks Industry
Apractical approach
C. Doeg
3 Food and DrinkLaboratoryAccreditation
Apractical approach
S. Wilson and G. Weir
Quality Man,ageTIlent
Systems for the Food
Industry
A guide to ISO 9001/2
Andrew Bolton
QualityManagement Consultant
Tunbridge Wells, UK
KAPARCHIEF
BLACKIE ACADEMIC eSc PROFESSIONAL
AnImprintofChapman&Hall
London· Weinheim· NewYork· Tokyo· Melbourne· Madras
PublishedbyBlackieAcademicandProfessional,animprintofChapman& Hall,
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Chapman&Hall,2-6BoundaryRow,LondonSEI8HN,UK
Chapman&HallGmbH,Pappelallee3,69469Weinheim,Germany
Chapman&HallUSA,115FifthAvenue,NewYork,NY10003,USA
Chapman&HallJapan,ITP-Japan,KyowaBuilding,3F,2-2-1Hirakawacho,
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DABook(Aust.)PtyLtd,648WhitehorseRoad,Mitcham3132,Victoria,Australia
Chapman&HallIndia,R.Seshadri,32SecondMainRoad,CITEast,Madras600035,
India
Firstedition1997
©1997AndrewBolton
©BSIQualityAssuranceAppendicesCandD
TypesetinPalatino10112ptbyGrayPublishing,TunbridgeWells
ISBN 0751403032
Apartfromanyfairdealingforthepurposesofresearchorprivatestudy,orcriticism
orreview,aspermittedundertheUKCopyrightDesignsandPatentsAct,1988,this
publicationmaynotbereproduced,stored,ortransmitted,inanyformorbyany
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Thepublishermakesnorepresentation,expressorimplied,withregardtothe
accuracyoftheinformationcontainedinthisbookandcannotacceptanylegal
responsibilityorliabilityforanyerrorsoromissionsthatmaybemade.
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Contents
Preface ix
Aclmowledgements xi
1 Introduction 1
1.1 Introduction 1
1.2 TheFoodSafetyAct1990 1
1.3 Thestatutorydefences- DueDiligence 3
1.4 WhatisBSENISO9001? 4
1.5 Summary 5
2 Qualitymanagementprinciples- whyBS ENISO900l? 6
2.1 Qualitymanagementprinciples 6
2.2 WhatisBSENISO9001? 7
2.3 Resultsandbenefits 11
2.4 TheadministrationofBSENISO9001 12
2.5 Summary 12
3 Preparationfor theprogramme- management
commitment 13
3.1 Strategicobjectiveand scope 13
3.2 Isitthe righttime? 14
3.3 Managementcommitmentand understanding 14
3.4 ManagementRepresentative 14
3.5 Aconsultantornot? 15
3.6 Appointmentofassessors 15
3.7 Projectcosts 16
3.8 Projectplanand timescale 16
3.9 Summary 18
v
Contents
4 Managementresponsibility 20
4.1 Introduction 20
4.2 Qualitypolicy 20
4.3 Responsibilityandauthority 21
4.4 ManagementRepresentative 21
4.5 Managementreview 22
4.6 Complaintmanagement 22
4.7 Summary 23
5 Thequalitysystemand documentcontrol 24
5.1 Introduction 24
5.2 Thequalitypolicystatement 26
5.3 Thequalitymanualandprocedures 28
5.4 Thequalityplan 29
5.5 Thedocumentsystem 30
5.6 Managementofdocumentation 34
5.7 Computeraccessandsecurity 38
5.8 Summary 40
6 Buyingandselling- purchasingandcontractreview 43
6.1 Introduction 43
6.2 Purchasing 43
6.3 Contractreview 45
6.4 Summary 46
7 Designand development 48
7.1 Introduction 48
7.2 Projectplan 49
7.3 Projectmanagementplan 49
7.4 Designdocumentation 52
7.5 Designspecifications 53
7.6 Summary 54
8 Processcontrol 56
8.1 Introduction 56
8.2 Planning 56
8.3 Specificationand controls 56
8.4 Dressand hygiene 57
8.5 Specialprocesses 57
8.6 Cleaning 58
8.7 Nonconformingproduct 58
8.8 Workinprogress 60
8.9 Waste management 60
8.10 Customer-suppliedproduct 60
vi
Contents
8.11 Handling,storage,packaging,preservation
and delivery 60
8.12 Productidentificationandtraceability 62
8.13 Pestcontrol 63
8.14 Correctiveandpreventiveaction 63
8.15 Productiontrials 63
8.16 Qualityrecords 64
8.17 Summary 64
9 Inspection,measuringand testing- calibration 66
9.1 Introduction 66
9.2 Inspectionand testing 66
9.3 Controlofinspection,measuringandtest
equipment- calibration 68
9.4 Inspectionand teststatus 70
9.5 Summary 70
10 Internalqualityaudit 73
10.1 Introduction 73
10.2 Internalauditprocedure 73
10.3 Theauditschedule 74
10.4 Selectionand trainingofauditors 75
10.5 Preparationoftheauditees 76
10.6 Theinternalaudittrainingprogramme 76
10.7 Companyawareness 83
10.8 Summary 84
11 Training 90
11.1 Introduction 90
11.2 Inductiontraining 90
11.3 Jobdescriptions/workinstructions 92
11.4 Generaltraining 92
11.5 Personalrecords 92
11.6 Summary 93
12 Theassessmentprocess 96
12.1 Introduction 96
12.2 Appointmentofassessors 97
12.3 Documentreview 97
12.4 Theassessment 98
12.5 Surveillancevisits 100
12.6 Summary 100
13 Achievementofthestandard- whatnext? 101
13.1 Introduction 101
vii
Contents
13.2 Totalqualitymanagement 101
13.3 Performanceindicesand qualitycosts 102
13.4 Qualityimprovementteamsandqualitycircles 104
13.5 Qualitytools 105
13.6 Thecultofcontinuousimprovement 105
14 Otheraccreditation/certificationsystems 107
14.1 Introduction 107
14.2 Industryschemes 107
14.3 Nationalandinternationalschemes 109
14.4 Guidelinesandcodesofpractice 110
14.5 CodexAlimentarius 111
14.6 Confidencemarks 111
14.7 Distributors' ownbrandsandcontracts 112
14.8 Inconclusion 112
14.9 Contactaddresses 112
AppendixA Modelqualitymanual: QFSQualityFood
Services 113
Appendix B Accreditedthird-partycertificationbodies 145
AppendixC Guidancenotesfor theapplicationof
BS ENISO9001: 1994for thefood and drinkindustry 147
AppendixD Guidance notesfortheapplicationof
ISO9002/EN29OO2/BS5750: Part2To the hoteland
cateringindustry 166
AppendixE NewZealandQ-Basecode: quality
managementsystemsfor smalland medium-sized
enterprises- generalrequirementsTB004:1995 178
AppendixF Glossary 186
References 189
Index 191
viii
Preface
Inrecentyearstherehasbeengrowingpressureforconsistentproduct
quality, and a need for companies to demonstrate sound quality
managementpracticesinordertomeet'DueDiligence'requirements
ofbothlegislationand the qualityassurance practices ofcustomers.
It has become accepted that operating to the requirements of the
international standardfor quality management- BS EN ISO 9001
goesalongway towards meetingtheseneeds.
The objective of this book is to explain the requirements of the
standard,to offeradviceaboutachievingthose requirementsand to
indicate what the assessors will look for at assessment time. It is
important that certification to the standard is sought to support
achievementofcompanyobjectivesandnotthereverse,andofcourse
thestandardcanapplytoorganizationsandservices,justasmuchas
tocompanies.Thustheword'company'inthetextshouldbetreated
accordingly.
lliustrativematerialhasbeenpresentedunderthelogoofafictiti
ouscompany'QualityFoodServices'- in this contextQFSdoesnot
bear any relationship whatsoever to any identically or similarly
namedbusinessthatmayexist.
Readers will find it helpful to read the book with a copy of the
standardtohand,andarestronglyencouragedtoreadthecomplete
textbeforetakinganystepstoprepareforcertificationtothestandard.
AndrewBolton
TunbridgeWells
June1996
ix
Acknowledgements
Nobookofthisnaturecanbewritten withoutadequateexperience
andknowledge,andqualitymanagementinthefoodindustryisboth
a wideand a deep subject. Inevitablyand necessarilyonelives and
learnsfrom thewisdomandadviceofcolleaguesandfriends. Ihave
beenprivilegedtoworkwithmanyfine colleaguesduringwhathas
beenahappycareer,andtoallofthem,withinandwithoutUnilever,
Itake thisopportunitytosaythankyou.
Iam indebted to BSI QualityAssurance for permission to repro
ducetheGuidelinestotheFoodandDrinkIndustry,andtotheHotel
andCateringIndustry,whichcanbefound inAppendicesCandD.
SimilaracknowledgementiswillinglyofferedtoTelarc,NewZealand
fortheinformationinChapter14abouttheQ-Basestandardandthe
textinAppendix E.
To my wife Gillian and our sons Nicholas, Matthew andJeremy
myparticularlythanksfor theloveandencouragementthatIenjoy,
particulary with regard to the preparation of this book. Gillian has
beenadiligentproofreaderandcritic,and theboyshavesupported
mywordprocessingcapabilities,orperhapsIshouldsaylackofthem!
xi