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2. Onion Paste Production and Maintenance
Process Purpose and Scope
This process involves the steps involved in
manufacturing and maintaining the equipment used for
producing onion paste. It ensures consistent quality,
safety, and hygiene while adhering to relevant
regulations

3. Process Organisation Chart
General
Manager
Production Supervisor
Maintenance Supervisor
Workers
Technicians

4. Responsibility of various designated persons
Workshop director: Receives orders and compiles the production plan .
Team leader: Assigns production tasks to workers and quality inspection tasks to the quality
inspector.
Craftsman: Carries out production tasks assigned by the team leader.
Quality supervisor: Oversees the quality of the products being manufactured.
Quality inspector: Conducts quality inspections as assigned by the team leader.
Warehouse keeper: Final Product Packaging & Stores finished products.
General Manager: Overall responsibility for production and maintenance.
Production Supervisor: Manages production operations, assigns tasks, ensures quality control.
Maintenance Supervisor: Oversees equipment maintenance, ensures functionality and safety.
Workers: Execute production tasks, follow SOPs, maintain hygiene.
Technicians: Perform equipment maintenance, repair breakdowns, conduct preventive maintenance.

5. Process Objectives
Order and Production Planning:
Ensure timely and efficient production by planning and
scheduling activities based on customer orders and
demand forecasts.
Raw Material Procurement:
Maintain an optimal level of raw materials in inventory to
support uninterrupted production while minimizing excess
stock.
Production Execution:
Achieve high-quality onion paste through efficient and
organized production processes, meeting established
production timelines.

6. Quality Control:
Guarantee the production of onion paste that consistently meets quality
standards by conducting regular inspections and addressing deviations
promptly.
Inventory Management:
Optimize inventory levels to ensure adequate raw material supply and
minimize waste, while meeting production demands.
Quality Supervision:
Oversee and enhance overall product quality by monitoring and analyzing
quality metrics, and implementing continuous improvement initiatives.
Final Product Packaging:
Efficiently package and label onion paste products according to customer
specifications, maintaining product integrity during the packaging
process.

7. Process Activity and its subprocess activity
1. Raw material selection and inspection
2. Washing and peeling onions
3. Chopping and grinding onions
4. Blending and pasteurization
5. Packaging and labeling
6. Quality control checks
7. Maintenance process:
8. Preventive maintenance schedule
9. Equipment cleaning and lubrication
10.Breakdown repairs and troubleshooting
11.Calibration and performance testing
12.Record keeping and reporting

8. Main Process Activity
The main process activity involves the initial preparation of onions,
including cleaning, peeling, and chopping, which are crucial steps in
ensuring the quality of the onion paste.
Sub-Process Activity
Sub-process activities include blending, cooking, and packaging, each of
which requires precise control and monitoring to achieve the desired
consistency and shelf-life of the onion paste.
Maintenance Process Activity
Maintenance of Onion Paste Equipment
Sub-Process Activities of Manitences
Regular Cleaning
Equipment Inspection
Lubrication and Calibration
Repair and Replacement

9. Process Monitoring and Measurement:
What: Monitor critical control points (CCPs) like processing temperature, sanitation
procedures, product quality.
Raw material quality (onion variety, freshness, size)
Processing parameters (peeling efficiency, chopping/grinding fineness,
cooking temperature/time)
Hygiene and sanitation (equipment cleanliness, worker sanitation)
Packaging integrity (leakage, seal defects)
Final product quality (color, texture, aroma, taste, microbial testing)
How: Use thermometers, visual inspection, laboratory testing, production logs.
Visual inspection
Temperature probes
Timers
Scales
Microbiological testing
Sensory evaluation

10. When: Continuously during production, regularly for maintenance.
Throughout the entire process (from receiving raw materials to finished product
storage)
At critical control points (peeling, grinding, cooking, filling)
At defined intervals based on risk assessment
Who: Production operators, quality control personnel, maintenance technicians.
Trained production personnel
Quality control staff
External laboratories (for microbial testing)
Record: Maintain logs and reports for all monitoring activities.

11. Record Name ID Maintained by Verified by
Retention
Period
Raw material inspection report Lot number Receiving clerk Production supervisor 1 year
Production log Batch number Production operator Quality control personnel 1 year
Equipment maintenance log Equipment ID Maintenance technician Maintenance supervisor 2 years
Calibration certificate Equipment ID External calibration service Maintenance supervisor 3 years
Non-conformance report Incident number
Production
operator/Maintenance
technician
Production
supervisor/Maintenance
supervisor
2 years
Process Record List

12. Competence Table
Name Education Experience Skills Training Imparted
Production worker High school
diploma
0-1+ years in food
processing
Hygiene, knife skills,
operating equipment
Food safety training,
SOP training
Maintenance technician Technical diploma 2+ years in
equipment
maintenance
Mechanical skills,
electrical
troubleshooting
Equipment-specific
training, maintenance
procedures
Quality control inspector Food science
degree
1+ year in quality
control
Laboratory analysis,
sensory evaluation
HACCP principles,
quality control
procedures