Manual pg 1 - Microsoft...Title Manual pg 1 Created Date 9/24/2019 10:36:07 AM
Quality Manual - PG
Transcript of Quality Manual - PG
-
7/28/2019 Quality Manual - PG
1/15
Logo Food Safety ManualPage
1/15Prepared : Name / Sign / Date Reviewed : Name /Sign / Date Approved : Name / Sign / Date
MR / /01Apr07 PS / /01Apr07 MD / /01Apr07
Doc. Type
Manual
Doc. No.
FSM-BB-01
Revision
00
Bhole Baba Dairy Industries Ltd.AddressAligarh
Amendment Status
Confidential, all rights reserved. No part of this document may be reproduced, stored in a retrieval system, or transmitted, in any form orby any means, without prior permission. Offenders will be held liable for the payment of damages.
Revision Description of Revision Prepared Reviewed Approved
Status Date By Date By Date By Date
00 01.04.07 First Issue MR 01.04.07 PS 01.04.07 MD 01.04.07
-
7/28/2019 Quality Manual - PG
2/15
Logo Food Safety ManualPage
2/15Prepared : Name / Sign / Date Reviewed : Name /Sign / Date Approved : Name / Sign / Date
MR / /01Apr07 PS / /01Apr07 MD / /01Apr07
Doc. Type
Manual
Doc. No.
FSM-BB-01
Revision
00
0. Profile
Bhole Baba Dairy Industries Limited (BBDIL) situated at Aligarh (Dist - Aligarh of Uttar
Pradesh) is having a pollution free environment and is blessed with a rich source of MILK
with potential for multifold increase in milk production. The milk available is surplus for
converting into value added products.
The surplus milk available from the various Milk sources in the milk-shed area is about 0.4
million liters per day as of now and proposes to reach 1 million towards the end of the year
2007.
BBDIL plans to set up a wide network of Bulk Coolers to gradually encompass its
area of procurement as one of the perspectives towards continual improvement in the
quality of incoming milk. This is to ensure procurement of best quality milk by
providing immediate chilling facility at village level. The results of such integrated
efforts are aimed at sharing with the valued customers of BBDIL and the society at
large.
The layout of the entire factory complex at Aligarh has been designed to have a green belt
around the factory so that the entire atmosphere is dust and pollution free. The total
covered area of the main factory building, including utilities, administration block &
guesthouse (in process), is set up on a picturesque landscape.
The plant houses the State-of-Art Technology both in equipment and manufacturing
processes.
BBDIL has been very closely associated with Westfalia Separators AG, Germany who has
supplied the entire package of equipment for manufacture of Acid Casein.
Lactose Plant and Separators have been procured from pioneers in Dairy Industry like Alfa
Laval.
BBDIL has its entire plant of NF/UF set up on a turnkey basis by APV Invensys
Confidential, all rights reserved. No part of this document may be reproduced, stored in a retrieval system, or transmitted, in any form orby any means, without prior permission. Offenders will be held liable for the payment of damages.
-
7/28/2019 Quality Manual - PG
3/15
Logo Food Safety ManualPage
3/15Prepared : Name / Sign / Date Reviewed : Name /Sign / Date Approved : Name / Sign / Date
MR / /01Apr07 PS / /01Apr07 MD / /01Apr07
Doc. Type
Manual
Doc. No.
FSM-BB-01
Revision
00
At the well automated BBDIL, the milk reception and pre-processing is planned to begin
from the keyboard of the computer and carries on through various stages till the final
product has been produced.
The present products being manufactured at BBDIL are Acid Casein, Lactose, Whey
Protein Concentrate, Skimmed Milk Powder & Ghee
Presently the company is concentrating to produce nutritionally superior, hygienically safe
and economically viable products.
On export front company has already created a strong base in US & Europe by exporting
Skimmed Milk Powder and proposes to continue doing so even strongly by taking its other
products like Casein, Lactose & Whey Protein Concentrates to the World Market. Besides
this, the Company is eagerly looking forward and preparing for opportunities to export its
products in the emerging markets in China & Japan. To achieve this ambitious plan the main
agenda will be: PRODUCT SAFETY AND QUALITY.
Confidential, all rights reserved. No part of this document may be reproduced, stored in a retrieval system, or transmitted, in any form orby any means, without prior permission. Offenders will be held liable for the payment of damages.
-
7/28/2019 Quality Manual - PG
4/15
Logo Food Safety ManualPage
4/15Prepared : Name / Sign / Date Reviewed : Name /Sign / Date Approved : Name / Sign / Date
MR / /01Apr07 PS / /01Apr07 MD / /01Apr07
Doc. Type
Manual
Doc. No.
FSM-BB-01
Revision
00
1. Scope
1.1 General
Bhole Baba has developed and implemented the Food Safety Management System (FSMS)described in this manual to help us to operate with increased effectiveness, efficiency, consistencyand customer satisfaction. Our QMS utilizes the process approach and quality managementprinciples contained in the international standards ISO 22000 to enhance our ability to continuallyimprove.
1.2 Application
Our FSMS complies with all applicable requirements contained in ISO 22000, covers the
following scope:
Products Processes Site (s)
Skimmed Milk Powder
Casein & Derivatives
Lactose
Whey Protein Concentrates
Ghee
ManufacturingPackaging &Dispatch.
1.3 Organization Structure
Appendix A
Confidential, all rights reserved. No part of this document may be reproduced, stored in a retrieval system, or transmitted, in any form orby any means, without prior permission. Offenders will be held liable for the payment of damages.
List the site address
-
7/28/2019 Quality Manual - PG
5/15
Logo Food Safety ManualPage
5/15Prepared : Name / Sign / Date Reviewed : Name /Sign / Date Approved : Name / Sign / Date
MR / /01Apr07 PS / /01Apr07 MD / /01Apr07
Doc. Type
Manual
Doc. No.
FSM-BB-01
Revision
00
2.1 Food Safety policy
We, At Bhole Baba Dairy Industries Limited, Are Committed To
Manufacture & Supply Quality Food Products To
Achieve Customer Satisfaction, Through
Continual Improvements In Products, Processes & Systems.
Our policy statement indicates our commitment and focuses on what is important to us as an
organization: achieving customer satisfaction; and it prescribes the method by which weaccomplish this: by continually improving processes, and services to ensure they consistentlymeet or exceed requirements. Moreover, our policy statement acts as a compass, providing thedirection and a framework for establishing key performance measures and related improvementobjectives.
2.2 Food Safety objectives
Our overall goal is to achieve our Food Safety policy, and maintain the integrity of andcontinually improved FSMS. At the Management level, MRC will monitor and measure
performances in the areas outlined below and, where needed, establish measurable improvementobjectives.
---
---
---
At the operational level, all Staff members will monitor and measure performance of processeswithin their area(s) of responsibility.
Confidential, all rights reserved. No part of this document may be reproduced, stored in a retrieval system, or transmitted, in any form orby any means, without prior permission. Offenders will be held liable for the payment of damages.
Insert the various objectives
-
7/28/2019 Quality Manual - PG
6/15
Logo Food Safety ManualPage
6/15Prepared : Name / Sign / Date Reviewed : Name /Sign / Date Approved : Name / Sign / Date
MR / /01Apr07 PS / /01Apr07 MD / /01Apr07
Doc. Type
Manual
Doc. No.
FSM-BB-01
Revision
00
3. Reference Documents (including Statutory and Regulatory requirements)The following external documents contain provisions which, through reference in this manual,constitute provisions of our FSMS:
ISO 22000 Food Safety Management System Requirements for organizations through out thefood chain.Prevention of Food Adulteration Act 1954, Edition 2005IS 10500, IS-14543 Water----Agmark GuidelinesCAC/RCP 57-2004, Code of Hygiene Practice for Milk and Milk ProductsCAC/RCP 56-2004Code of Practice for the Prevention and Reduction of lead Contamination inFoods.
Specify the Registration numbers with various statutory bodies.
4. Control on out-sourced Process:
S.No.
Process Control Mechanism
1. Calibration ISO/IEC 17025 certified LaboratoryNABL Accreditation
5. Food Safety Team:
Sr. Designation Competence Criteria
Skill 1 Skill 2 Skill 3
1 President (Operations)
2 Manager (Quality Control)
3 Manager (QMS) (HACCP Co ordinator)
4 Manager (Production)
5 Manager (Engineering)
6 Sr. Microbiologist
Skill 1: Expertise in different aspects of food safety ranging from farm to fork.
Skill 2: Awareness of the requirements of HACCP
Skill 3: Experience in Food Industry (min. 2 yrs)
6. Appendix:
A Organization Structure
Confidential, all rights reserved. No part of this document may be reproduced, stored in a retrieval system, or transmitted, in any form orby any means, without prior permission. Offenders will be held liable for the payment of damages.
Look out for any moreout sourced product/
List all the statutory requirements.
-
7/28/2019 Quality Manual - PG
7/15
Logo Food Safety ManualPage
7/15Prepared : Name / Sign / Date Reviewed : Name /Sign / Date Approved : Name / Sign / Date
MR / /01Apr07 PS / /01Apr07 MD / /01Apr07
Doc. Type
Manual
Doc. No.
FSM-BB-01
Revision
00
B List of Procedures, which define the key processes for implementing our quality policy.Note:Procedure Document Control contains procedures governing the control of these andother FSMS documents.
C Description of compliance to ISO 22000 requirements
Confidential, all rights reserved. No part of this document may be reproduced, stored in a retrieval system, or transmitted, in any form orby any means, without prior permission. Offenders will be held liable for the payment of damages.
-
7/28/2019 Quality Manual - PG
8/15
Logo Food Safety ManualPage
8/15Prepared : Name / Sign / Date Reviewed : Name /Sign / Date Approved : Name / Sign / Date
MR / /01Apr07 PS / /01Apr07 MD / /01Apr07
Doc. Type
Manual
Doc. No.
FSM-BB-01
Revision
00
Appendix
Confidential, all rights reserved. No part of this document may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, without prior permission. Offenders will be held liablethe payment of damages.
Organization Chart
-
7/28/2019 Quality Manual - PG
9/15
Logo Food Safety ManualPage
9/15Prepared : Name / Sign / Date Reviewed : Name /Sign / Date Approved : Name / Sign / Date
MR / /01Apr07 PS / /01Apr07 MD / /01Apr07
Doc. Type
Manual
Doc. No.
FSM-BB-01
Revision
00
Appendix BList of Procedures
S. No. Description Document No.1. Procedure for document control QS/P/001
2. Procedure for record control QS/P/002
3. Procedure for Audits QS/P/003
4. Procedure for management review meeting QS/P/004
5. Procedure for Identification, Traceability & Recall QS/P/005
6. Procedure for Corrective actions QS/P/0067. Procedure for Preventive actions QS/P/007
8. Procedure for interaction with customers (complaints,feedback)
QS/P/008
9. Procedure for emergency preparedness / contingency QS/P/009
10. HACCP Manual of Raw Milk Reception HACCP/01
11. HACCP Manual of Ghee HACCP/02
12. HACCP Manual of Skim Milk Powder HACCP/03
13. HACCP Manual of Casein HACCP/04
14. HACCP Manual of Whey Processing HACCP/05
15. HACCP Manual of Lactose HACCP/06
16. HACCP Manual of Whey Protein Concentrate HACCP/07
17. Current Good Manufacturing Practices (CGMP)
18. Procedure for Standard Sanitary Operating Procedures(SSOP)
19. Procedures at Engineering Stores STR/ENG/P/001
20. Procedures at Packing Material & Finished Goods Stores STR/PMFG/P/001
21. Procedures for Mechanical Maintenance ENG/MECH/P/001
22. Procedures for Electrical Maintenance ENG/ELE/P/001
23. Procedures for Instrumentation & Control ENG/I&C/P/001
24. Procedure for Human Resource & Personnel RelatedTasks
HR/HR/P/001
25. Procedure for Training HR/TRG/P/001
Confidential, all rights reserved. No part of this document may be reproduced, stored in a retrieval system, or transmitted, in any form or by anymeans, without prior permission. Offenders will be held liable for the payment of damages.
-
7/28/2019 Quality Manual - PG
10/15
Logo Food Safety ManualPage
10/15Prepared : Name / Sign / Date Reviewed : Name /Sign / Date Approved : Name / Sign / Date
MR / /01Apr07 PS / /01Apr07 MD / /01Apr07
Doc. Type
Manual
Doc. No.
FSM-BB-01
Revision
00
S. No. Description Document No.26. Procedure for Purchase of all material except milk PUR/PUR/P/001
27. Procedure for Purchase of milk PUR/PUR/P/002
28. Procedure for evaluation of suppliers PUR/PUR/P/003
Confidential, all rights reserved. No part of this document may be reproduced, stored in a retrieval system, or transmitted, in any form or by anymeans, without prior permission. Offenders will be held liable for the payment of damages.
-
7/28/2019 Quality Manual - PG
11/15
Logo Food Safety ManualPage
11/15Prepared : Name / Sign / Date Reviewed : Name /Sign / Date Approved : Name / Sign / Date
MR / /01Apr07 PS / /01Apr07 MD / /01Apr07
Doc. Type
Manual
Doc. No.
FSM-BB-01
Revision
00
Appendix CAdequacy Matrix
(FSMS vs. ISO 22000)
CLAUSEOF IS/ISO9001:2001
REQUIREMENTS OF THESTANDARD
SYSTEM DOCUMENTATION
4 Food Safety Managementsystem(title only)
---
4.1 General Requirements FSM-BB-01
4.2
4.2.14.2.24.2.3
DocumentationRequirements(title only)GeneralControl of DocumentsControl of records
---
FSM-BB-01QS/P/001QS/P/002
5 Management Responsibility(titleonly)
---
5.1 Management Commitment FSM-BB-01
5.2 Food Safety Policy FSM-BB-01
5.3 Food Safety ManagementSystem Planning
FSM-BB-01
5.4 Responsibility and authority HR/JR/P/001-009
5.5 Food Safety Team Leader Mr.
5.6
5.6.1
5.6.2
Communication (Title Only)
External Communication
Internal Communication
---
Subject ResponsibleSuppliers & Contractors Mr.
Customers Mr.(QS/P/008)
Food Authorities Mr.
Other stake holders Mr.
Meetings, Training Programs, Circulars,EPBX, Notice Boards, Work Instructions etc.
5.7 Contingency Preparedness &response
QS/P/009
5.8 Management Review (TitleOnly)
---
Confidential, all rights reserved. No part of this document may be reproduced, stored in a retrieval system, or transmitted, in any form or by anymeans, without prior permission. Offenders will be held liable for the payment of damages.
-
7/28/2019 Quality Manual - PG
12/15
Logo Food Safety ManualPage
12/15Prepared : Name / Sign / Date Reviewed : Name /Sign / Date Approved : Name / Sign / Date
MR / /01Apr07 PS / /01Apr07 MD / /01Apr07
Doc. Type
Manual
Doc. No.
FSM-BB-01
Revision
00
CLAUSE
OF IS/ISO9001:2001
REQUIREMENTS OF THE
STANDARD
SYSTEM DOCUMENTATION
5.8.15.8.25.8.3
GeneralReview InputReview Output
QS/P/004
6 Resource Management(title only)
---
6.1 Provision of resources ---
6.26.2.1
Human Resources (title only)General
---HR/HR/P/001
6.2.2 Competence Awareness andTraining
HR/TRG/P/001
6.3 Infrastructure ---
6.4 Work Environment ---
7 Planning & realization of safeproducts (title only)
---
7.1 General ---
7.2
7.2.1
7.2.2
7.2.3
Pre-requisite program(title only)
General requirements
Infrastructure & MaintenancePrograms
Operational PRPs
---
---
ENG/MECH/P/001ENG/ELE/P/001ENG/I&C/P/001
Refer List of PRP
7.3 Preliminary steps to enableHazard Analysis (title only)
---
7.3.1 General ---
7.3.2 Food Safety Team FSM-BB-01
7.3.3 Product Characteristics ---
7.3.3.1 Raw materials, ingredients &
product contact materials
STR/ENG/P/001
STR/PMFG/P/001HACCP/01-07
7.3.3.2 End Product Characteristics HACCP/01-07
7.3.4 Intended Use
7.3.5 Flow Diagrams, process steps &control measures (Title Only)
---
7.3.5.1 Flow Diagrams HACCP/01-07
Confidential, all rights reserved. No part of this document may be reproduced, stored in a retrieval system, or transmitted, in any form or by anymeans, without prior permission. Offenders will be held liable for the payment of damages.
-
7/28/2019 Quality Manual - PG
13/15
Logo Food Safety ManualPage
13/15Prepared : Name / Sign / Date Reviewed : Name /Sign / Date Approved : Name / Sign / Date
MR / /01Apr07 PS / /01Apr07 MD / /01Apr07
Doc. Type
Manual
Doc. No.
FSM-BB-01
Revision
00
CLAUSE
OF IS/ISO9001:2001
REQUIREMENTS OF THE
STANDARD
SYSTEM DOCUMENTATION
7.3.5.2 Description of process steps andcontrol measures
HACCP/01-07
7.47.4.17.4.2
7.4.37.4.4
Hazard Analysis (title only)GeneralHazard identification &determination of acceptablelevelsHazard AssessmentIdentification & Assessment of
control measures
---HACCP/01-07
7.5 Design & Redesign of operational PRP
Refer List of PRP
7.6
7.6.17.6.27.6.3
7.6.4
7.6.5
Design & Redesign of HACCPPlan (Title only)HACCP PlanIdentification of CCPsDetermination of critical limitsfor CCPsSystem for the monitoring ofCCPs
Actions when monitoring resultsexceeds critical limits
---
HACCP/01-07
7.7 Updating of preliminaryinformation and documentsspecifying the PRP andHACCP Plan
QS/P/001QS/P/004
7.8 Verification planning Refer the procedure for verification
7.9
7.9.1
Operation of the food safetymanagement system (Title only)General
---
---
7.9.2 Traceability System QS/P/005
7.9.3 Corrections & Correctiveactions (Title only)
---
7.9.3.1 Corrective actions QS/P/006
7.9.3.2 Corrections Refer the procedure for control of NCP
7.9.4 Handling of potentially unsafeproducts
Refer the procedure for control of NCP
7.9.5 Recalls QS/P/005
Confidential, all rights reserved. No part of this document may be reproduced, stored in a retrieval system, or transmitted, in any form or by anymeans, without prior permission. Offenders will be held liable for the payment of damages.
-
7/28/2019 Quality Manual - PG
14/15
Logo Food Safety ManualPage
14/15Prepared : Name / Sign / Date Reviewed : Name /Sign / Date Approved : Name / Sign / Date
MR / /01Apr07 PS / /01Apr07 MD / /01Apr07
Doc. Type
Manual
Doc. No.
FSM-BB-01
Revision
00
CLAUSE
OF IS/ISO9001:2001
REQUIREMENTS OF THE
STANDARD
SYSTEM DOCUMENTATION
8 Verification, validation andimprovement of food safetymanagement system (Title only)
---
8.1 General ---
8.2 Monitoring and measuring ENG/I&C/P/001
8.3 Food safety management systemverification (Title only)
---
8.3.1 Internal Audit QS/P/003
8.3.2 Evaluation of individualverification results
Refer the procedure for verification
8.3.3 Analysis of results of verification activities
QS/P/004
8.4 Validation of control measurecombination
HACCP/01-07
8.5 Improvement (Title only) ---
8.5.1 Continual Improvement QS/P/004
8.5.2 Food safety management systemupdating
Refer the procedure for verificationQS/P/001
Confidential, all rights reserved. No part of this document may be reproduced, stored in a retrieval system, or transmitted, in any form or by anymeans, without prior permission. Offenders will be held liable for the payment of damages.
-
7/28/2019 Quality Manual - PG
15/15