sqf_gap_analysis_presentation_revision
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Alys Reed conducted a gap analysis of Leprino Foods' SQF (Safe Quality Food) certification efforts. She found opportunities for improvement in developing additional policies and completing registers. So far, 85% of required Section 4 documents are finished, while 31.25% of registers are complete. Alys recommends forming an SQF team, ongoing employee training, and a certification action plan to help Leprino achieve certification. She acknowledges the many people who supported her work.
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sqf_gap_analysis_presentation_revision
- 1. SQF GAP ANALYSIS Alys Reed Lemoore East Intern 2010 What are the areas of improvement?
- 2. WHO IS ALYS? Louisiana State University Biological Engineering Freshman First internship! I don’t know how to swim.
- 3. SQF CERTIFICATION How will it impact Leprino?
- 4. WHAT IS SQF? Safe Quality Food Code Application of HACCP Guidelines Customer’s food safety and quality requirements Solution Attractive to future customers Cost Effective! What does SQF even stand for?
- 5. SAFE QUALITY FOOD Two Codes 1. 1000 - Primary production 2. 2000 - Food manufacturing and distribution Three Levels of the 2000 Code 1. Level 1 - Food Safety Fundamentals 2. Level 2 - Certified HACCP Food Safety Plans 3. Level 3 - Comprehensive Food Safety and Quality Management Systems
- 6. STATEMENT OF COMMITMENT Produce safe, quality food Comply with the requirements of the SQF 2000 Code Comply with applicable food legislation
- 7. WHY IS SQF BEING INCORPORATED? Highly Recommended by Buyers and Suppliers Largest Distributors Requirements are coming soon! Leprino Foods Hot Pockets Wal-mart SQF CertifiedSQF Certified
- 8. SQF HANDBOOK Start Section 4 Documents Section 5 Building Section 6 Programs Section 7 Canned Foods Section 8 Implementing Section 9 Application of HAACP Section 10 Certifying SQF System Section 11 SQFI Audit , Certification, Supplier Section 12 Trade Mark Section 13 Multi-site Organization Finish
- 10. PROBLEM Wall tile falls onto the ground.
- 11. SOLUTION Clean up the debris and continue the day normally. Notify supervisor to determine effect on product and document the issue. Present Future
- 12. REASON FOR DIFFERENCE Ceramics included in the glass and brittle plastic policy SQF Practitioner - Handles Glass Register, includes glass, brittle plastics, ceramics, and porcelain - Ensure glass inventory is regularly updated Glass breakage record has to be created and on file.
- 13. ARRIVING AT LEMOORE EAST Experiencing a new journey
- 14. MY BRAIN AT BEGINNING OF INTERNSHIP 0 1 2 3 4 5 6 7 8 9 10 Leprino SQF AmountofKnowledge EachNumber=10% Areas of Learning Possibilities of Learning My Knowledge
- 15. ADVENTURE THROUGH LEPRINO Red Tag Policy HACCP plan Air Plate Sampling PQC process E-DLP Sampling, DLP taste testing
- 16. THE BEGINNING OF SQF Collaboration with Christine Tobey and Fort Morgan First Half of Section 4 Draft Documents Cross Examined Reviewed and Revised repeatedly
- 17. SQF CONTINUATION Second Half Begin Register portion 1. Raw Materials 2. Finished Product Specifications 3. Training Skills 4. Contract Services Specifications Revising and Reviewing Documents
- 18. MY BRAIN AT END OF INTERNSHIP 0 1 2 3 4 5 6 7 8 9 10 Leprino SQF AmountofKnowledge EachNumber=10% Possibilities of Knowledge My Knowledge Areas of Learning
- 19. RESULTS OF SQF GAP ANALYSIS Opportunities for Improvement in Leprino
- 20. SECTION 4 GAP ANALYSIS DOCUMENTS IN NEED OF POLICIES 4.1.6.1 Business Continuity Planning - Roles and Responsibilities of employees 4.3.1.1 Product Development - Product concept to commercial realization 4.3.1.3 Product Development - Determining shelf life for new products
- 21. SECTION 4 GAP ANALYSIS DOCUMENTS IN NEED POLICIES 4.4.1.2 Food Regulations - Legislation, scientific and technical development, and relevant industry codes of practice
- 22. SECTION 4 GAP ANALYSIS Policy Statement (4.1.3.1, 4.1.3.2, 4.1.3.3) - General statement of how Leprino adheres to the regulations of the Food Safety and Quality Plan Food Quality Manual (4.1.3.3) - Similar to a HAACP plan in layout and content
- 23. ACCOMPLISHMENTS Where is Leprino in becoming SQF certified?
- 24. RECENT PROGRESS IN NEEDED POLICIES Placement for Policy pertaining to 4.4.1.2 Food Regulations - Food Security Policy, QUA3122.200 - Section .150, in between section .140 Evaluation/Audit and .160 Guide to FDA Inspections
- 25. WHAT HAS BEEN ACCOMPLISHED SQF Section 4 Documents Finished Documents In Progress 85% 15%
- 26. WHAT HAS BEEN ACCOMPLISHED SQF Section 4 Registers Finished Registers Incompleted Registers 31.25% 68.75%
- 27. LOOK HOW FAR WE’VE COME 13 12 Section 11 Section 10 Section 9 HAACP Section 8 Implement Section 6 Programs Section 5 Building Section 4 Document
- 28. RECOMMENDATIONS A SQF Team Keeping the Lemoore East employees trained in SQF requirements A Plan of Action Message to Lemoore East
- 29. ACKNOWLEDGEMENTS Dave Dierking Ruth Vega Rick Stokes Ashish Pandit Angela McGee Christine Tobey Jason Eckert Joel Krein Tim Lombardo Leprino employees Intern Family
- 30. QUESTIONS
Editor's Notes
- Good Morning! My name is Alys Reed, and my project this summer was the SQF Gap Analysis. As in, to become SQF certified, what are the areas of improvement for Leprino.
- Who is Alys? Well, I go to Louisiana State University. Also, I will be a Biological Engineering Sophomore this coming semester, and this is my first internship! Unfortunately I can not swim, but ironically, this summer I've been doing a lot of activities in big bodies of water without any type of flotation device. So since I am still here, that means I’m doing pretty well!
- SQF Certification….How will it impact Leprino?
- So, you may ask what exactly is SQF. Actually, when I first heard about SQF, my first question was what does SQF stand for. Well, SQF stands for Safe Quality Food, and it is simply a code. This code provides food suppliers with a reliable food safety and quality management certification program. Also, it emphasizes on the systematic application of HACCP guidelines, and at the same time, addresses customer’s food and quality requirements. Implementing the SQF provides us with a simple solution for supplying local and global food markets. Having an SQF certified logo makes Leprino a more attractive supplier to future customers. Cost effective! It reduced the possibility of unsafe product, which reduces the amount of time and energy needed to solve an issue of retrieving an inadequate product.
- The SQF program encompasses two codes. The 1000 code involves primary production, and the 2000 Code deals with food manufacturing and distribution. So, we are dealing with the 2000 code. Within the 200 code, there are three levels, and we want to achieve the highest level, level three ( Comprehensive Food Safety and Quality Management Systems).
- When we are SQF certified, we will have a statement of commitment to our customers, which is that we produce safe, quality food, comply with the requirements of the SQF 2000 Code, and comply with any applicable food legislation!
- SQF certification is one the highest recommended certifications by buyers and suppliers. Also, large distributors like Wal-Mart are going to start requiring their suppliers and the suppliers of their suppliers to be SQF certified. These requirements are coming soon!
- This is an interpretation of the SQF handbook. These are all of the sections of the handbook. So, section 4 deals with documentation portion of the audit. Section 5 involves the design and construction of the plant, such as where the hand washing and storage facilities are located. Section 6 deals with Pre-requisite programs like GMP’s and HACCP training. Section 7 talks about the requirements for canned foods, but that doesn’t apply to us. Section 8 involves the implementation of SQF, and Section 9 describes what the HAACP Plan should consist of. Section 10 deals with certifying SQF 2000 System such as changing the scope of certification or maintaining the certification. Section 11 explains how there is a certification management system and how the SQF Institute supplier database is accessible to customers. Section 12 just refers to the use of the SQF trade mark, and Section 13 involves the requirements for a multi-site organization.
- And so, here is an example to help get a better understanding of how being SQF certified would change the way Leprino executes its responses to problems that occur.
- The problem. An accident occurs….Wall tile falls onto the ground.
- The present solution is to clean up the debris and continue the day normally. But if we were SQF certified, the solution would be to notify the supervisor to determine the effect on the product and document the issue.
- Ceramics are included in the glass and brittle plastic policy. The SQF Practitioner uses the Glass Register, which involves glass, brittle plastic, ceramics, and porcelain to ensure the glass inventory is regularly updates. The glass breakage record has to be created and kept on file.
- Arriving at Lemoore East….experiencing a new journey!
- In order to explain the amount of knowledge I had when came to Lemoore East and the amount I left with, I decided to make a graph! So, this is how much I knew of both Leprino and SQF. It’s not very much, but I was and still am more than willing to learn.
- On the first week I was here, I had the opportunity to go on many adventures throughout Lemoore East. Each day I learned something new and had to discover the answers to my questions by asking the employees and finding my way around the plant. Occasionally, I passed my destinations a couple of times before actually reaching them, but (haha) that’s okay. In learning about the red tag policy, I read about the process and discovered how the maintenance personnel fixes a piece of equipment, records the date and time of repair, the equipment’s assigned number, what was the needed repairing, and who repairs it. Clean up the area around the equipment, and sticks the red tag to the repaired equipment in order to notify others that this piece of equipment has not been properly cleaned. All the tags are signed by a supervisor in the area of repair, recorded, and logged in three Red Tag Logbooks located around the plant. When I learned about the HAACP plan and all of our critical control points, I was also learning about the process of making cheese, WPC, and Lactose. Also, I learned the importance of critical control points and how they are so essential to the processes because they are the last defense against bacteria or pathogens. They insure the quality and safety of our products. Within this week, I was able to do some air plate sampling for Listeria and EB, and be involved in recording the findings. The PQC process of receiving a set of documents involves the Warehouse manager*, the Lab Foreman, and QA Manager. I discovered how the documents are first received, by the Warehouse manager, accounted for in price and amount. Then it is sent to the Foreman to do any needed testing. If everything is approved , it is sent to the QA Manager to sign, and now the ingredients can be used. E-DLP Sampling and DLP taste testing was a sticky and tasteful experience. (haha) But it is a necessary sticky job and it protects our cheese from tasting funny.
- At the beginning of SQF and throughout the whole process, I collaborated with Christine Tobey and employees from Fort Morgan. We started with the first section of the handbook, Section 4, and Christine provided us with basic drafts of the documents required by SQF. Pao Her, a trainee at Fort Morgan, and I split the amount of draft documents in half, so I received the first half and he received the second. The process I took with these draft documents was to cross examine the draft document with the SQF handbook. The SQF handbook states the requirements of each document, and so each draft document was reviewed and revised accordingly. Also, electronic signatures were added to all documents that were deemed ready to be signed.
- So, at the end of June, Pao and I switched halves. I received the second half and he received the first. We also started on the Register portion of Section 4, and completed registers Raw Materials, Finished Product Specifications , Training Skills. The contract services specifications register is still in progress. During this second month, we were still reviewing and revising the documents that were unfinished.
- At the end of this internship, I can truly say that I learned many things about Leprino and SQF. As you can see, there is still a lot more learning to be done!
- Results of the SQF Gap Analysis….The opportunities for improvement in Leprino
- In the Gap Analysis, I found gaps in our policies, as in there are missing policies for some of the documents. Document 4.1.6.1 Business Continuity Planning involves the roles and responsibilities of employees. The missing policy here pertains to the re-entry into the building after an emergency crisis and involves how to ensure the quality of the product after the crisis. Document 4.3.1.1 Product Development speaks of the process of a product concept becoming commercial realization. As of right now, we do not have a policy describing this particular process and who carries the responsibilities of each step. Document 4.3.1.3 speaks of determining the shelf life for a new product, and we do not have a policy describing this process also.
- Document 4.4.1.2 Food Regulations involves legislation, scientific and technical development, and relevant industry codes of practice. For this document, we do not have a policy pertaining to when changes or additions are made to Food Safety Regulations, legislation, scientific development, and industry codes of practice , the VP of Food Safety and Quality Assurance and SQF Practitioner are responsible for notifying all employees .
- In documents 4.1.3.1, 4.1.3.2, 4.1.3.3, we are missing a policy statement that speaks of how Leprino adheres to the regulations of the Food Safety and Quality Plan specifically. Document 4.1.3.3 involves the Food Quality Manual and actually, we do not have a Food Quality Manual, which is similar to the HAACP plan in layout and content, except it will deal with the quality concepts , rules, and regulations.
- Accomplishments…..Where is Leprino in becoming SQF certified?
- I spoke with Tim Lombardo about creating some of those policies needed. Most policies will need to be fully constructed, but there is one that can be inserted into another existing policy. The policy pertaining to document 4.4.1.2 Food Regulations ( the one that talks about notifying the employees to changes in Food Safety Regulations) can be placed in the Food Security policy. QUA3122.200. It will be the new section .150 and will be between section .140 Evaluation/Audit and .160 Guide to FDA Inspections.
- So far, we have accomplished 85% of Section 4 Documents, and there is 15% left that may need policies or revisions. We’re almost there! Also, I composited a full summary of Section 4 documents with what needs to be accomplished on the documents that are not completed and refers to the documents that are finished. I did this summary for both Lemoore East and Fort Morgan.
- Also, we are 68.75% done with registers, but there is still 31.25% left to do. The 31.25% accounts for about 3 registers.
- On the scale of accomplishing sections in the handbook, we are mostly finished with Section 4, but as you can see, we still have a long way to go. Section 4, Documentation is one of the largest sections in the handbook. Section 5 and 6 involve a more active apporach because it compares Lemoore East plant design and programs to the SQF. Section 8.9 are fairly short. Section 10, 11 and 12 provides information about after becoming SQF certified. Section 13 just talks about establishing and maintaining certification for a multi-site organization. *
- Because we still have much to accomplish , I believe a team is needed, at least more than one person working on the certification. I also recommend keeping the Lemoore East employees regularly updated of the coming certification and from working with Christine, a plan of action was extremely helpful. Having a plan as to when each section would be finished or in progress would give us a estimation of how much time we have and how much work must be done each day. Encouragement. I have full faith that the employees at Lemoore East are more than capable of achieving the goal of being SQF certified. It will take some work, but I believe it will be accomplished.
- All My Thanks!
- Are there any questions? Note to Self: Re-check Documents!