Post on 24-Dec-2015
COPYRIGHT RICHARD F. STIER 2011
Building Preventive Maintenance Programs to Save Money and
Enhance Efficiencies
Richard F. StierConsulting Food Scientist
Sonoma, CA rickstier4@aol.com
COPYRIGHT RICHARD F. STIER 2011
PREVENTIVE MAINTENANCE
COMMON EXAMPLES• Teeth Cleaning - 2x per year to prevent decay
• Oil Changes - Protect car’s engine
• Tree Trimming - Protect house from damage
• Gutter Cleaning - Protect roof & home
COPYRIGHT RICHARD F. STIER 2011
PREVENTIVE MAINTENANCE
WHY• Assure food safety• Reduce potential for adulteration• Protect equipment/extend life
– Significant savings
• Enhance profitability• Records of performance• Integral part of all 3rd party audits
COPYRIGHT RICHARD F. STIER 2011
How To Make Safe Food
HACCP
GMP/GAP
SANITATION PRODUCT IDENTIFICATION & CODING,
RECALL & TRACEABILITY,
PREVENTIVE MAINTENANCE, EDUCATION & TRAINING, AND OTHER PREREQ PROGRAMS
SAFE FOOD
Total Management Commitment
COPYRIGHT RICHARD F. STIER 2011
Prerequisites and FSSC 220008.6 Preventive and Corrective Maintenance
A preventive maintenance program shall be in place
The preventive maintenance programme shall include all devices used to monitor and control food safety hazards
COPYRIGHT RICHARD F. STIER 2011
CAC/RCP 1-1969, Rev.4- 2003 Page 1 of 31
RECOMMENDED INTERNATIONAL CODE OF PRACTICE
GENERAL PRINCIPLES OF FOOD HYGIENE
CAC/RCP 1-1969, Rev. 4-20031
TABLE OF CONTENTS
COPYRIGHT RICHARD F. STIER 2011
SECTION VI – ESTABLISHMENT MAINTENANCE & SANITATION
• Maintenance & Cleaning – General Establishment & equipment should be kept in
an appropriate state of repair to:– Facilitate sanitation procedures – Function as intended– Prevent contamination of food
Cleaning should remove food residues. Method depends on type of soil. Disinfection may be necessary after cleaning. Use cleaning materials per manufacturers instructions.
COPYRIGHT RICHARD F. STIER 2011
HACCP PLAN DEVELOPMENT
FLOW CHART OPERATIONS
• Understand the process
• Means of conveyance & transfers
• Understand what needs to be maintained
COPYRIGHT RICHARD F. STIER 2011
PREVENTIVE MAINTENANCE
BIOLOGICAL HAZARDS
• Loss of process control
• Contamination with foodborne pathogens
• Growth of foodborne pathogens
• Inability to properly monitor systems
COPYRIGHT RICHARD F. STIER 2011
PREVENTIVE MAINTENANCE
TEMPERATURE CONTROL
• Malfunctioning temperature indicating or temperature recording devices
• Belt Failures - Residence for continuous processes shortened
• Pumps - Residence time reduced
• Refrigeration Failures
COPYRIGHT RICHARD F. STIER 2011
PREVENTIVE MAINTENANCE
PACKAGING FAILURES
• Botulism in canned salmon (early 1980’s)
• Seamer adjustment failures (post-process contamination)
• Sealer failures
COPYRIGHT RICHARD F. STIER 2011
FOOD PLANT CHEMICALS
• Food additives– Vitamins– Sulfites
• Lubricants
• Sanitizers
• Cleaners
• Antimicrobials
COPYRIGHT RICHARD F. STIER 2011
PREVENTIVE MAINTENANCE
CHEMICAL HAZARDS
• Improper lubrication (excessive)
• Cleaners
• Failure to use food-grade/approved materials
COPYRIGHT RICHARD F. STIER 2011
PREVENTIVE MAINTENANCE
PHYSICAL HAZARDS
• Missing bolts
• Worn belts
• Metal to metal contact
• Broken blades, choppers, etc.
• Glass windows
• Protected bulbs
COPYRIGHT RICHARD F. STIER 2011
PREVENTIVE MAINTENANCE
PHYSICAL HAZARDS
• Metal detectors improperly maintained or calibrated
• Can or glass washers
• Buildings not maintained (rust, flaking paint)
COPYRIGHT RICHARD F. STIER 2011
ESTABLISHING PREVENTIVE MAINTENANCE PROGRAMS
THREE STEP PROGRAM
• Inventory & Understand Equipment - Flow Chart
• Develop Standard Operating procedures for Inspection & Maintenance
• Develop Recordkeeping Procedures to Document Maintenance
COPYRIGHT RICHARD F. STIER 2011
INVENTORY & UNDERSTAND EQUIPMENT• Process Flow Charts
• Potential for Hazards
• Units Essential to Food Safety
• Equipment Setup Properly; Example, Motors over processing lines
• Accessibility
COPYRIGHT RICHARD F. STIER 2011
DEVELOP SOP’S for INSPECTION & MAINTENANCE
• Work with Suppliers: – Operating Manuals
– Training
• Inspections - Routine & Detailed
• Write Protocols - Date & Sign Off
• Place in a Manual
COPYRIGHT RICHARD F. STIER 2011
DEVELOP RECORDKEEPING PROTOCOLS
• Develop monitoring forms - keep simple– Include forms for emergency repairs– Lubrication records– Tool reconciliation
• Essential element for HACCP & ISO and many buyers
• Maintenance records can be used to evaluate performance
• Record review policy by management
COPYRIGHT RICHARD F. STIER 2011
DATEBASES: WHY??• Organization
• Stronger prerequisite programs
• Reduced liability
• Enhanced efficiencies
• Safer work environment
• Improved quality
• Audit requirements
COPYRIGHT RICHARD F. STIER 2011
MAINTENANCE MANAGEMENT• Many commercial products
– SAP, Blue Mountain, AMMS, others
• Many companies still use “hard copies” to manage this prerequisite program
• Painful to get set up• Lots and lots of data that must be entered• Most companies whom I have worked with are not
even using their programs at full capacity
COPYRIGHT RICHARD F. STIER 2011
MAINTENANCE MANAGEMENT
• What you want– Maintenance scheduling– Flags when items are due– Flags for past due items– Cost integration – Maintenance hours, capital costs, parts,
downtime, etc.– Procedures for doing work– Automatic entry by workers– Ability to verify that work has been done– Print capability – Summaries, schedules, equipment
registers– Ability to “talk” to other systems
COPYRIGHT RICHARD F. STIER 2011
INCLUDE CALIBRATION• Essential element for ensuring food safety and
quality• All devices used for monitoring CCPs must be
calibrated on a regular schedule• All devices used for quality monitoring must
be calibrated• Commercial systems – Some incorporate
calibration into their maintenance management systems
• Developed in-house – EXCEL, ACCESS
COPYRIGHT RICHARD F. STIER 2011
IN-PLANT COOPERATION
• All operating groups must participate in equipment upkeep & maintenance– Many companies pass on routine maintenance
and startup to production personnel
• Report problems immediately• Report on performance• Encourage input on maintenance & upkeep• Adherence to cleaning & sanitizing
COPYRIGHT RICHARD F. STIER 2011
SANITATION & MAINTENANCE
• Maintenance staff must adhere to basic principles of sanitation
• Hair restraints, cleanliness, proper clothing
• Tools & supplies under control
• Conscious of processing
COPYRIGHT RICHARD F. STIER 2011
IMPLEMENTATION
• Do not try to do all at once
• Work with one line or area
• Be flexible
• Modify program as needed
COPYRIGHT RICHARD F. STIER 2011
Responsible Person• Someone must be assigned to manage the preventive
maintenance program– Engineering Manager
– Shop supervisor
• Person should;– Write or update procedures
– Manage scheduling of training
– Review and maintain training records
– Ensure that program is audited per schedules, i.e., the program is be followed as designed.
COPYRIGHT RICHARD F. STIER 2011
Responsible Person
• Job description should reflect responsibility• Person must sign job description or another
document acknowledging responsibility• Must manage training program to ensure that all
necessary training is delivered.• Training must be based on documented
procedures
COPYRIGHT RICHARD F. STIER 2011
TRAINING/EDUCATION
• Production and maintenance personnel must be trained– Work instructions– Procedures
• Quality, safety and sanitation
COPYRIGHT RICHARD F. STIER 2011
Procedures
• Procedures must be developed, documented, implemented & maintained– Standard format for each procedure– Should include a general protocol that
addresses each area of the preventive maintenance program
– Can be integrated into maintenance management software
COPYRIGHT RICHARD F. STIER 2011
Procedures• Procedures must be developed, documented,
implemented & maintained– Created by;
• Maintenance staff• Vendors• Other
– Recordkeeping forms– Must include;
• Regular maintenance• Emergency maintenance• Lubrication
– Record review procedures– Audit scheduling & format– Register format for equipment
COPYRIGHT RICHARD F. STIER 2011
RECORDKEEPING
“If it’s not written down it never happened.”
United States Food & Drug Administration
COPYRIGHT RICHARD F. STIER 2011
RECORDKEEPING “In God we trust. But everyone else
has to give us data and records.”
COPYRIGHT RICHARD F. STIER 2011
RECORDS • Maintenance records must be maintained• May be;
– Hard copies– Electronic databases
• Records must include;– Tasks– Records of completion– Verification that work was done– Training/competency records
• Certified electrician, plumber, etc
COPYRIGHT RICHARD F. STIER 2011
System Verification
• Procedures – Persons responsible for doing work following
established procedures– Use procedures and work instructions as a
guide
• Records– Adherence to schedules– Training records– Audit forms
COPYRIGHT RICHARD F. STIER 2011
System Verification• Internal auditors must be trained to do audits
– Procedures
– Forms
– What to look for
– Training records maintained
• Can be done in-house or send to a 3rd party for training
• Realistically, in-house may be better since training may be “hands-on”
COPYRIGHT RICHARD F. STIER 2011
System Audits• Persons doing work complying with documented
procedures and/or work instructions• Persons trained or competent
– Training records on procedures
– Records demonstrating competency
• Records being kept properly– Data recorded when record or observation taken
– Corrections made properly
– Proper pens and forms employed
– Other
COPYRIGHT RICHARD F. STIER 2011
System Audits
• Corrective Actions– Deficiencies must be addressed – Corrective or preventive actions– Serious deficiencies should be subjected to root cause
analysis to determine why the issue occurred– Maintain records of actions
• Forms• CAPA log
– Persons must be trained in root cause analysis procedures
– Quality group shall verify that deficiencies were addressed. Sign & date corrective action programs
COPYRIGHT RICHARD F. STIER 2011
PREVENTIVE MAINTENANCE
• Three Part Implementation– Inventory & Understand Equipment
– Develop Procedures for Inspection & Maintenance
– Develop Recordkeeping Procedures
• Involve All Operating Groups
• Implement Program Gradually