Applying Process-based Analytics to Audit Results for Process Management and Improvement


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All that time and money spent on an audit…and what does it get you? If you’re like most companies, it sadly ends up in file-cabinet limbo.
With all that resource investment, it’s time to make that data work for you. Apply process based analytics to drive useful, actionable management insight into your process.
Recording available at
Operational audits and inspections play a critical role in assuring the effectiveness of the Food Safety Management System (FSMS). But that’s merely Step One.
Step Two and beyond involve leveraging the results from these audits to maximize value and effectiveness for process management and improvement by identifying the key process indicators, assessing them for trends, and taking action before a food-safety incident occurs.
The proper linkage and operation of the FSMS components enables successful certification audits. Additionally, it bolsters the view by Senior Management and other stakeholders that the plant has a robust food-safety management system in place. By applying process based analytics such as SPC to sanitation data, management can continuously monitor the FSMS performance, improve compliance and reduce risk to the company.
The webinar examines the data available in audits and pre-requisite program inspections and how applying analytics such as SPC can extract useful process management information. This method provides actionable feedback on the manufacturing processes and establishes a solid foundation for process management and continuous improvement.
Recording available at
Your presenter: John G. Surak, PhD
John Surak is principal of Surak and Associates, a full service food safety and quality consulting service. He works with the food processing industry in developing food safety and quality management systems, designing and implementing process control systems, and implementing Six Sigma and business analytics systems.
Dr. Surak has more than 30 years of experience. He works with industry and governmental agencies in applying the principles of quality and food safety management. In addition, he held industrial positions including managing nutritional process and product development for Wyeth Laboratories and serving as vice president of quality and food safety for the Brooks Food Group. Dr. Surak is a professor emeritus of applied economics and statistics at Clemson University.

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Applying Process-based Analytics to Audit Results for Process Management and Improvement

  1. 1. #AuditAnalytics© 2009. J. G. Surak 1
  2. 2. Applying Process-based Analyticsto Audit Results for ProcessManagement and Improvement John G. Surak, PhD Surak and Associates Clemson, SC USA © 2011. J. G. Surak 2
  3. 3. Audits andthe food processing industry Food processors conduct a large number of audits  Pre Op  Facilities  Pest control  Microbial environmental monitoring Food Safety Management Systems require  Internal audit © 2011. J. G. Surak 3
  4. 4. Function of the internal audit The internal audit is designed to answer the following questions  Is the FSMS implemented?  Is the FSMS effective?  Is the FSMS efficient?  Is the FSMS sustainable?  Is the FSMS updated? © 2011. J. G. Surak 4
  5. 5. Linked FSMS The ISO 22000 or FSSC 22000 FSMS is a linked system © 2011. J. G. Surak 5
  6. 6. Example of linkages 7.8 Verification 8.4.2 Evaluation of 8.4.3 Analysis of7.2 PRPs planning individual verification results of verification results activities Classical Audits 8.4.1 Internal audit 8.5 Improvement © 2011. J. G. Surak
  7. 7. 8.4.3 Analysis of the results ofverification activities Conforming the overall performance of the FSMS Identifying the needs for improvement of the FSMS Identifying trends that indicate a higher incidence of potentially unsafe products Establishing information for the planning of audits Provide evidence that corrections and corrective actions are effective © 2011 J. G. Surak 7
  8. 8. Application to PRPs © 2011. J. G. Surak
  9. 9. © 2011. J. G. Surak
  10. 10. © 2011. J. G. Surak
  11. 11. Application to production data 1 2 3 11 © 2011. J. G. Surak
  12. 12. Improving audit effectiveness The function of the internal audit is to determine that the organization is functioning according to plan Auditor’s luck  Observe the process and determine what is not present and determine exceptions to what is present Going beyond auditor’s luck  Use graphical techniques to quantify if the FSMS is operating according to plan © 2011. J. G. Surak 12
  13. 13. Contact information John G. Surak, PhD 864-506-2190© 2011. J. G. Surak 13
  14. 14. © 2009. J. G. Surak 14