The Question…<br />How doyou achieve compliance, improve efficiencies and gain competitive advantage?<br />
what’s in a number?<br />these numbers tell a story about <br />food safety<br />a single food product may contain over 50...
800<br />600<br />total number<br />of food recalls<br />400<br />200<br />2006<br />2007<br />2008<br />2009<br />2010<br...
food safety modernization act (FDA)<br />bio-terrorism act of 2002<br />USDA<br />ISO 22000<br />safe quality food (SQF)<b...
how can <br />manufacturers comply?<br />
the status quo<br />SPC<br />Quality<br />HR – Skills Matrix<br />HACCP<br />OEE<br />Document<br />Control<br />PlantMain...
instant traceability<br />&<br />recall mgt<br /><ul><li> shop floor data collection
human machine interface (HMI)
 mobile device operations
 OEE reporting
 rejection tracking
machine integration (SCADA)
 allergen control
 production scheduling
pick, pack & ship</li></ul>manufacturing operations management system (MOMS)<br />MOMS<br />food quality<br />&<br />elect...
Control Panel<br />MOMS<br />
Control Panel<br />
Control Panel<br />Plant & Quality Bulletins<br />Production<br />Recording<br />Maintenance<br />Work Orders<br />Barcode...
  Enabling mobility<br />MOMS<br />
  Enabling OEE<br />MOM<br />
traceability<br />&<br />recall management<br />manufacturing operations management system (MOMS)<br /><ul><li> HR – skill...
 visitor log
 supplier approval & scorecarding
 accounting & finance
advanced product costing
CRM
maintenance management
purchasing</li></ul>food quality <br />& <br />electronic HACCP<br /><ul><li> embedded document control
compliance management
 electronic HACCP
 checklists / SOP’s
corrective & preventative action
 critical control point alarming
SPC charting
electronic signature
 workflow</li></ul>ERP<br />food safety<br />
  Enabling eHACCP<br />eHACCP<br />
  Enabling eHACCP<br />
  Enabling eHACCP<br />
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201104 food manufacturing and automation show

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This presentation was given the 2011 Food Automation and Manufacturing Conference in Palm Beach, Florida. The presenters were Tom Nessen and Jon Cowan from Plex Systems. The presentation discusses the key components of a Food Safety Management System.

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  • Recalls increasing for several reasons, 3 of which include:Consumers are more aware and conscientiousMore federal and industry regulations and mandatesGlobalization and supply chain complexities have increased, where there are more points where issues can be introduced
  • Industry reaction to these recalls is more regulation:FSMA – new FDA regulation that mandates all companies must have Food Safety Management systems in place, including document control, HACCP and recall. This is the biggest change to Food Safety legislation in over 60 years.(from myGFSI website) GFSI – The Global Food Safety Initiative (GFSI) is a collaboration between some of the world&apos;s leading food safety experts from retailer, manufacturer and food service companies, as well as service providers associated with the food supply chain. It is coordinated by The Consumer Goods Forum, the only independent global network for consumer goods retailers and manufacturers worldwide. It serves the CEOs and senior management of nearly 400 members, in over 150 countries.Why did the Global Food Safety Initiative begin?In May 2000, following a number of food safety scares, a group of international retailer CEOs identified the need to enhance food safety, ensure consumer protection and to strengthen consumer confidence. They launched the Global Food Safety Initiative which sets requirements for food safety schemes through a benchmarking process in order to improve cost efficiency throughout the food supply chain. WalMart and other major retailers mandate suppliers follow one of the 8 schemas supported by GFSI, which includes SQF and variants of ISO22000. These standards are very similar to the FSMA recently set by the FDA
  • So How do Manufacturers comply with government and industry mandates with limited resources and all this complexity in the F&amp;B supply chain?
  • The reason Plex is perfectly suited is because we have solutions for all three major areas (pillars) of Food Saftey: Manufacturing Operations Management (MOM) – shop floor integration, OEE, Production Tracking, etc..eHACCP – Hazard Analysis and Critical Control Points in electronic format – Quality, risk management and document control Traceability – managing recalls and lot traceWhile other companies offer point solutions Plex can offer a full Food Safety Management Suite, Plus ERP functionality
  • The reason Plex is perfectly suited is because we have solutions for all three major areas (pillars) of Food Saftey: Manufacturing Operations Management (MOM) – shop floor integration, OEE, Production Tracking, etc..eHACCP – Hazard Analysis and Critical Control Points in electronic format – Quality, risk management and document control Traceability – managing recalls and lot traceWhile other companies offer point solutions Plex can offer a full Food Safety Management Suite, Plus ERP functionality
  • The reason Plex is perfectly suited is because we have solutions for all three major areas (pillars) of Food Saftey: Manufacturing Operations Management (MOM) – shop floor integration, OEE, Production Tracking, etc..eHACCP – Hazard Analysis and Critical Control Points in electronic format – Quality, risk management and document control Traceability – managing recalls and lot traceWhile other companies offer point solutions Plex can offer a full Food Safety Management Suite, Plus ERP functionality
  • Through food safety management systems, which have traditionally been paper based. New legislation is going to make this increasingly more difficult to manage on Paper. We feel Plex and cloud technologies are perfectly suited to manage this for manufacturers of all sizes
  • 201104 food manufacturing and automation show

    1. 1. The Question…<br />How doyou achieve compliance, improve efficiencies and gain competitive advantage?<br />
    2. 2. what’s in a number?<br />these numbers tell a story about <br />food safety<br />a single food product may contain over 50 ingredients,<br />50<br />10 <br />500<br />1<br />where many ingredients are sourced globally and have been touched by 10 or more business entities.<br />a single manufacturer may have over 500unique suppliers of ingredients,<br />and it only takes 1 incident to destroy a company.<br />
    3. 3. 800<br />600<br />total number<br />of food recalls<br />400<br />200<br />2006<br />2007<br />2008<br />2009<br />2010<br />0<br />
    4. 4. food safety modernization act (FDA)<br />bio-terrorism act of 2002<br />USDA<br />ISO 22000<br />safe quality food (SQF)<br />british retail consortium (BRC)<br />global food safety initiative (GFSI)<br />
    5. 5. how can <br />manufacturers comply?<br />
    6. 6. the status quo<br />SPC<br />Quality<br />HR – Skills Matrix<br />HACCP<br />OEE<br />Document<br />Control<br />PlantMaintenance<br />Traceability<br />Compliance<br />Management<br />Fragmented Data Sources<br />
    7. 7. instant traceability<br />&<br />recall mgt<br /><ul><li> shop floor data collection
    8. 8. human machine interface (HMI)
    9. 9. mobile device operations
    10. 10. OEE reporting
    11. 11. rejection tracking
    12. 12. machine integration (SCADA)
    13. 13. allergen control
    14. 14. production scheduling
    15. 15. pick, pack & ship</li></ul>manufacturing operations management system (MOMS)<br />MOMS<br />food quality<br />&<br />electronic HACCP<br />ERP<br />Food Safety Management Solution<br />
    16. 16. Control Panel<br />MOMS<br />
    17. 17. Control Panel<br />
    18. 18. Control Panel<br />Plant & Quality Bulletins<br />Production<br />Recording<br />Maintenance<br />Work Orders<br />Barcode<br />Labeling<br />Gauge<br />Calibration<br />Control<br />Production<br />Scheduling<br />Checksheet<br />History<br />Quality<br />Reporting<br />Document<br />Control<br />Access<br />HACCP<br />Reporting<br />Time Clock<br />Training<br />OSHA Reporting<br />Employee<br />Innovations<br />PLC<br />Integration<br />
    19. 19. Enabling mobility<br />MOMS<br />
    20. 20. Enabling OEE<br />MOM<br />
    21. 21. traceability<br />&<br />recall management<br />manufacturing operations management system (MOMS)<br /><ul><li> HR – skills matrix
    22. 22. visitor log
    23. 23. supplier approval & scorecarding
    24. 24. accounting & finance
    25. 25. advanced product costing
    26. 26. CRM
    27. 27. maintenance management
    28. 28. purchasing</li></ul>food quality <br />& <br />electronic HACCP<br /><ul><li> embedded document control
    29. 29. compliance management
    30. 30. electronic HACCP
    31. 31. checklists / SOP’s
    32. 32. corrective & preventative action
    33. 33. critical control point alarming
    34. 34. SPC charting
    35. 35. electronic signature
    36. 36. workflow</li></ul>ERP<br />food safety<br />
    37. 37. Enabling eHACCP<br />eHACCP<br />
    38. 38. Enabling eHACCP<br />
    39. 39. Enabling eHACCP<br />
    40. 40. Enabling SPC<br />
    41. 41. Instant traceability<br />&<br />recall mgt<br /><ul><li> graphical product genealogy
    42. 42. extended supply chain tracking
    43. 43. lot trace and trace
    44. 44. allergen tracking
    45. 45. reduce scope of a recall
    46. 46. quickly contain tainted product</li></ul>manufacturing operations management system (MOMS)<br />traceability<br /><ul><li> HR – skills matrix
    47. 47. visitor log
    48. 48. supplier approval & scorecarding
    49. 49. accounting & finance
    50. 50. advanced product costing
    51. 51. CRM
    52. 52. maintenance management
    53. 53. purchasing</li></ul>food quality <br />&<br />electronic HACCP<br />ERP<br />
    54. 54. what’s in this cookie?<br />Bleached Enriched Wheat Flour<br />Wheat Flour, Niacin, Reduced Iron, Thiamine Mononitrate, Riboflavin, Folic Acid, <br />Candy Pieces<br />Dark Chocolate - Sugar, Chocolate liquor, cocoa butter, butter oil, soy lecithin, vanillia<br />Sugar, Yellow #5 Lake Yellow, Yellow # 6 Lake, Blue #2 Lake, Red #40 Lake, Blue #1, Yellow #6, Yellow #5, Blue #1, Gum Arabic, Corn Syrup<br />Confectioners Glaze - Carnauba wax, beeswax and shellac<br />High fructose corn syrup<br />Butter<br />Pasteurized cream, water, lactic Acid<br />Sugar<br />Shortening<br />Canola Oil, Hydrogenated cottonseed oil, citric acid<br />Eggs<br />Contains less than 2% of 6 other ingredients<br />traceability<br />
    55. 55. a tale of two ingredients<br />gum arabic<br />vanillia<br />traceability<br />food additives<br />processor<br />candy maker<br />candy maker<br />extracts manufacturer<br />
    56. 56. traceability<br />
    57. 57. traceability<br />
    58. 58. traceability<br />
    59. 59. Instant traceability<br />&<br />recall mgt<br /><ul><li> shop floor data collection
    60. 60. human machine interface (HMI)
    61. 61. mobile device operations
    62. 62. OEE reporting
    63. 63. rejection tracking
    64. 64. machine integration (SCADA)
    65. 65. allergen control
    66. 66. production scheduling
    67. 67. pick, pack & ship
    68. 68. graphical product genealogy
    69. 69. extended supply chain tracking
    70. 70. lot trace and trace
    71. 71. allergen tracking
    72. 72. reduce scope of a recall
    73. 73. quickly contain tainted product</li></ul>manufacturing operations management system (MOMS)<br />traceability<br />MOMS<br /><ul><li> embedded document control
    74. 74. compliance management
    75. 75. electronic HACCP
    76. 76. checklists / SOP’s
    77. 77. corrective & preventative action
    78. 78. critical control point alarm
    79. 79. SPC charting
    80. 80. electronic signature
    81. 81. workflow</li></ul>food quality<br />&<br />electronic <br />HACCP<br /><ul><li> HR – skills matrix
    82. 82. visitor log
    83. 83. supplier approval
    84. 84. accounting & finance
    85. 85. advanced product costing
    86. 86. CRM
    87. 87. maintenance management
    88. 88. purchasing</li></ul>ERP<br />ERP<br />food safety <br />Food Safety Management Solution<br />
    89. 89. enterprise food safety management & ERP<br />
    90. 90. “The Cloud”<br />Research<br />Maps<br />Business <br />Software<br />
    91. 91. Benefits of Cloud<br />
    92. 92.
    93. 93. twitter: <br />blog: foodsafteymanagement.wordpress.com<br />Jon Cowan – jlcowan@plex.com<br />Tom Nessen – tnessen@plex.com<br />

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