BRC Implementation Workbook Sample

88C lood SafeLy ManagemenL SysLem lmplemenLaLlon Workbook
www.brcfoodsafety.com
1
We have written this workbook to assist in the implementation of your
BRC food safety management system. The workbook is divided into 8
steps that are designed to assist you in implementing your food safety
management system effectively:
Step One: ntroduction to the BRC Global Standard for Food
Safety
Step Two: Assessment of Prerequisites
Step Three: Senior Management mplementation
Step Four: Food Safety Plan/HACCP mplementation
Step Five: Food Safety Quality Management System
Step Six: BRC mplementation & Training
Step Seven: nternal Auditing Training & Checklists
Step Eight: Final Steps to BRC Certification
1
Safety
1
Safety
2
The Workbook guides you the process of implementing our BRC Food
Safety Quality Management System, which is an ideal package for Food
Manufacturers looking to meet British Retail Consortium Food Standard
2011 (ssue 6) for Food Safety Quality Management Systems.
This comprehensive system contains:
Procedures Manual
Record Templates
HACCP Manual containing the HACCP Calculator
nteractive HACCP Training and Examination
BRC Standard for Food Safety Training Module
BRC Global Standard for Food Safety Gap Analysis Checklist
Laboratory Quality Manual
nteractive nternal Auditor Training
Food Safety Manual BRC Compliance Guide
Free online support via e-mail
As a preliminary to Step 1 we recommend that the you purchase a copy
of the current issue of the BRC Global Standard for Food Safety
For more information contact us here
2
Procedures Manual
Record Templates
2
Procedures Manual
Record Templates
S
Step One: Introduction to the BRC GIobaI Standard for Food Safety
This 45 minute comprehensive illustrated and interactive PowerPoint
training module presentation will introduce the BRC Global Standard for
Food Safety to the management team and explain how to start the
process of implementing a BRC compliant Food Safety Management
System.
4
At this stage an assessment should be made by the most senior technical member of the management team to decide if
Site Prerequisite Standards within the facility meet the Food Safety Requirements in Sections 4 to 7 of the BRC Standard.
The nominated manager should read through the requirements in Section 4 to 7 of the BRC Global Standard for Food
Safety 2011 and assess for compliance using the checklist below to record their findings.
8kC G|oba| Standard Ior Iood Safety Issue 6 2011
Sect|on 4 S|te Standards
ke|evant Documentat|on kequ|rements Comp||ant
Comments
Sect|on 4 S|te Standards es No
4.1 LxLernal SLandards
1he producLlon slLe shall be of sulLable slze, locaLlon, consLrucLlon and deslgn
4.1.1
Local acLlvlLles and
envlronmenL
4.1.2
LxLernal areas shall be
malnLalned
4.1.3 8ulldlng fabrlc malnLalned
4.2 SecurlLy sysLems
44
Step 2: Corrective Actions from Assessment of Prerequisites
The non-compliances identified in the assessment of compliance with Sections 4 - 7 of the BRC Global Standard
for Food Safety 2008 should be logged using the form below and used as input for Step Three: Senior
Management mplementation. n Step 3 the appropriate corrective action should be allocated by the Senior
Management Team and a corrective action plan formulated.
Step 2: Correct|ve Act|ons from Assessment of rerequ|s|tes
Date
8kC Standard
Sect|on
Deta||s of Non
Conformance
Ident|f|ed
by:
Correct|ve Act|on
kequ|red
kespons|b|||ty
1arget
comp|et|on
Date
Date
Comp|eted
4S
Step Three: Senior Management ImpIementation
A Senior Management mplementation checklist is provided that
establishes your Food Safety Management System fundamentals
including Food Safety Policies and Objectives.
The checklist guides Senior Management:
in planning the establishment of the FSMS
in providing adequate support to establish the FSMS
in ensuring there is adequate infrastructure and work
environment
in allocating responsibility and authority
This stage requires the Senior Management to meet and establish the
foundations for the Food Safety Management System:
Formulating a checklist of Customer, Regulatory, Statutory and
other relevant Food Safety requirements
Decide which Food Safety requirements the company should
address and develop relevant policies.
Based on the Food Safety Policy Management Policies establish
Food Safety Objectives
Define the scope and boundaries of the FSMS
Plan the establishment of the FSMS using the project planner
Provide adequate support to establish the FSMS
Ensure there is adequate infrastructure and work environment and
develop a Corrective Action Plan to rectify Prerequisite shortfalls
Allocate responsibility and authority
Assess, plan and establish appropriate internal and external
communication (including the food chain) channels
As a decision has already been made to implement a system compliant
with the BRC Global Standard for Food Safety, the Senior Management
meeting should also consider the requirements of the Standard which
are summarised below and should be read direct from the Standard:
47
Senior Management FSMS mplementation Meeting
Date
Time
Venue
Agenda
1. Formulating a checklist of Customer, Regulatory, Statutory and
other relevant Food Safety requirements
2. Decide which Food Safety requirements the company should
address and develop relevant policies.
3. Based on the Food Safety Policy Management Policies establish
Food Safety Objectives
4. Define the scope and boundaries of the FSMS
5. Plan the establishment of the FSMS using the project planner
6. Provide adequate support to establish the FSMS
7. Ensure there is adequate infrastructure and work environment
8. Allocate responsibility and authority
9. Assess, plan and establish appropriate internal and external
communication (including the food chain) channels
Attendees:
Senior Management Team
Job TitIe Name RoIe in Team
Managing Director Chairman
Site Director Deputy Chair
Operations Manager Operations Reporting
Technical Manager Food Safety and Quality Reporting
Management Representative
Planning Manager Planning and Capacity Reporting
Distribution Manager Distribution Reporting
Maintenance Manager Services and Engineering Provision
Finance Manager Financial Reporting
Human Resources Manager Resource reporting
S7
Senior Management Establish the Project Plan
Senior Management can adapt/use the template supplied with the
system to establish a Project Plan.
67
Senior Management Establish Food Safety Responsibility & Authority
Levels
Process
ResponsibIe
Persons
Activity
Purchases Purchasing
Manager
Purchase ingredients from approved and certified
sources
Ensure purchase orders comply with applicable
specifications
Technical
Manager
Ensure adequate information on supply application form
Ensure suppliers adhere to supply handling practices
Perform suppliers audit or review supply status where
necessary
Receiving and
warehousing
QA/QC &
Store
Executives
Compare PO and DO or check contracts as per
Suppliers Specifications criteria (if applicable)
Check receiving temperature, pest infestations, quality,
packing conditions and truck hygiene.
Observe unloading practices
Handle incoming goods as per documented procedures
Ensure Good Storage Practices and FFO rotation
principles
Preparation of
ngredients
QA/QC,
Production
Manager &
Production
Executive
Follow safe food preparation and handling practices
Check environmental hygiene and safety
Check equipment process performance and
maintenance
Check water quality and safety
Check raw materials identification and traceability
Production QC/QC,
Production
Manager,
Supervisor &
Operators
Maintain product recipes and characteristics
Do not modify recipes prior to approval from top
management
Follow safe food handling practices
Ensure Good Manufacturing Practices are adhered to
Follow cleaning and sanitation standards and
procedures
Follow the handling standards of raw and processed
foods
Holding and Filling of
Processed Food
Production
Supervisor &
Operators
Follow safe food holding procedures
Hold foods outside the range of danger zone
Follow safe food filling procedures into primary
packaging
Capping, coding and
packing
Production
Supervisor &
Operators
Follow safe capping procedures
Ensure food in primary packaging are hygienically
located
Ensure coding for traceability is performed to
procedures
Follow secondary packaging procedures to protect
products
74
At this stage you should check that the Senior Management Actions and Plans meet those required by the BRC
Global Standard for Food Safety Section 1 Senior Management Commitment & Continual mprovement
8kC G|oba| Standard Ior Iood Safety Issue 6 2011
Sect|on 1 Sen|or Management Comm|tment
lunuAMLn1AL - 5eolot moooqemeot oeeJ to Jemoosttote tbey ote folly commltteJ to tbe lmplemeototloo of tbe fooJ
sofety ooJ poollty moooqemeot system, meetloq tbe tepoltemeots of tbe Clobol 5tooJotJ fot looJ 5ofety ooJ Jtlvloq
cootloool lmptovemeot.
ke|evant Documentat|on kequ|rements Comp||ant
Comments
Sect|on 1 Sen|or Management Comm|tment es No
1.1
Senlor ManagemenL
CommlLmenL And ConLlnual
lmprovemenL
1.1.1
uocumenLed lood SafeLy
ollcy
1.1.2
uocumenLed lood SafeLy
Cb[ecLlves
1.1.3 ManagemenL 8evlew
*
1.1.4 MeeLlng rogram
76
Step Four: Food Safety PIan/HACCP ImpIementation
HACCP Training
An interactive and illustrated PowerPoint HACCP training presentation is
supplied to train your food safety team in the preliminary steps to a
Hazard analysis, the principles of HACCP and how to utilise the HACCP
calculator in implementing your HACCP system.
78
Training Software
The interactive and illustrated PowerPoint HACCP training presentation
is supplied with training software.
We have provided a HACCP Multiple choice exam to evaluate your
staff's progress with graphic certificates to print out.
81
HACCP mplementation Tasks
HACCP mplementation Tasks are to be completed by the Food Safety
Team using the guidelines included in this HACCP mplementation
Section. We will go through the task by section as the requirements are
listed in Section 2 of the BRC Global Standard for Food Safety:
Sect|on 2 1he Iood Safety |an - nACC
lundamenLal requlremenL - 1bete most be oo lmplemeoteJ ooJ effectlve looJ
5ofety lloo boseJ oo coJex Allmeototlos nAccl ptloclples.
2.1 1he PACC lood SafeLy 1eam
2.1.1 MulLl-dlsclpllnary food safeLy Leam
2.2 re- requlslLe programs
2.2.1
Cleanlng and sanlLlslng
esL conLrol
MalnLenance programs for equlpmenL and bulldlngs
ersonal hyglene requlremenLs
SLaff Lralnlng
urchaslng
1ransporLaLlon arrangemenLs
rocesses Lo prevenL cross conLamlnaLlon
Allergen conLrols
2.3 uescrlbe Lhe roducL
2.3.1 Scope of Lhe PACC plan
2.3.2
All relevanL lnformaLlon needed Lo conducL Lhe hazard
analysls
2.4 ldenLlfy lnLended use
2.4.1 1he lnLended use of Lhe producL by Lhe cusLomer
8S
HACCP mplementation Guide Section 2.2 Pre- requisite programs
Prerequisite programmes are established including:
Cleaning and sanitising
Pest control
Maintenance programs for equipment and buildings
Personal hygiene requirements
Staff training
Purchasing
Transportation arrangements
Processes to prevent cross contamination
Allergen controls
1u2
nACC |an
Cr|t|ca| L|m|ts Mon|tor|ng rocedures Correct|ve Act|on kespons|b|||ty nACC kecord
Mlnlmum /
Maxlmum
accepLable levels
Lo ensure
condlLlon ls ln
conLrol
- measuremenLs Lo be
Laken (or observaLlons)
meLhod of measuremenL
- devlces used (lncludlng
appllcable callbraLlon
procedures)
- frequency of monlLorlng
- responslblllLy and
auLhorlLy for monlLorlng
and evaluaLlon of Lhe
monlLorlng resulLs
AcLlon Lo be
Laken when
ouLslde of crlLlcal
llmlLs Lo regaln
conLrol and
ensure unsafe
producL ls
conLrolled
Who ls Laklng Lhe
acLlon
Where ls lL
recorded
1uS
Design of the HACCP Plan
The Food Safety Team need to formulate and document a HACCP plan
defining the hazards to be controlled, CCPs where hazards are
controlled, critical limits and monitoring procedures at each CCP and
action to be taken when critical limits are exceeded. The HACCP plan
needs to define those responsible for performing monitoring procedures
and the records where the monitoring results are recorded.
The food safety team identify critical control points (CCP) s for each food
safety hazard
Critical Control Points are established using the decision tree as the
latest step in the flow path where controls can be effectively
administered for a particular Significant Food Safety Hazards.
118
Step Five: Food Safety QuaIity Management System
Our Food Safety Management System contains a comprehensive BRC
compliant documentation package. n this bundle of certification tools
you will find:
Food Safety Quality Manual containing a set comprehensive
procedures and an extensive range of record templates.
HACCP manual containing food safety procedures and our
unique HACCP Calculator.
Laboratory manual including sample procedures and records.
At this stage you can choose to totally implement the procedures
supplied or pick those that are applicable to your process.
The Food Safety Quality Manual contains comprehensive top level
procedures templates that form the foundations of your Food Safety
Management System so you don't have to spend 1,000's of hours writing
compliant procedures:
119
Food Safety Management System Record Templates
A comprehensive range of easy to use food safety management system
record templates:
QMR 001 Management Review Minutes
QMR 002 Training Record
QMR 003 Product Release Record
QMR 004 Design and Development Records
QMR 005 Supplier Assessment Record
QMR 006 Validation Record
QMR 007 dentification and Traceability Record
QMR 008 Register of Customer Property
QMR 009 Calibration Record
QMR 010 nternal Audit Record
QMR 011 Records of Non-conforming Product
QMR 012 Corrective Action Request Form
QMR 013 Preventative Action Request Form
QMR 014 Supplier Self Assessment and Approval Form
QMR 015 Equipment Commissioning Record
QMR 016 Return to Work Form
QMR 017 Hygiene Policy Staff Training Record
QMR 018 Complaint nvestigation Form
QMR 019 Prerequisite Audit Checklist
QMR 020 Knife Control Record
QMR 021 Knife Breakage Report
QMR 022 Goods in nspection Record
QMR 023 Equipment Cleaning Procedure
QMR 024 Glass and Brittle Plastic Breakage Record
QMR 025 Metal Detection Record
QMR 026 First Aid Dressing ssue Record
QMR 027 Cleaning Schedule
QMR 028 Cleaning Record
QMR 029 Engineering Hygiene Clearance Record
QMR 030 Glass and Brittle Plastic Register
QMR 031 GMP Audit Checklist
QMR 032 Vehicle Hygiene nspection Record
QMR 033 Outgoing Vehicle nspection Record
QMR 034 Pre Employment Medical Questionnaire
QMR 035 Visitor Questionnaire
QMR 036 Product Recall Record
QMR 037 Shelf Life Confirmation Record
QMR 038 Accelerated Keeping Quality Log
12u
QMR 039 Goods n QA Clearance Label
QMR 040 Maintenance Work Hygiene Clearance Form
QMR 041 Changing Room Cleaning Record
QMR 042 Colour Coding Red Process Areas
QMR 043 Daily Cleaning Record for Toilets & Changing Rooms
QMR 044 Drain Cleaning Procedure Filler Areas
QMR 045 General Cleaning Procedure
QMR 046 Product QA Clearance Label
QMR 047 CP Programmes Log
QMR 048 Sample Filler Cleaning Record
QMR 049 Pipe Diameter Flow Rate Conversion Table
QMR 050 QC Online Check Sheet
Food Safety Management System Record Templates
12S
Step Six: Training and ImpIementation
A significant part of the implementation process is training. Job
Descriptions should be available for all staff and they should be briefed
and aware of their food safety responsibilities.
A training matrix and plans should be drawn up for all staff and the
relevant training given based on responsibility and authority.
We have provided a Staff Training Matrix Template in Microsoft Excel
Format.
For each employee and individual training record should be completed.
QMR 002 Training Record is provided in the documentation pack as a
template:
126
QMR 002 Training Record
Basic Training should be given to all staff and also include:
Job/Task Performance
Company Safety and Quality Policies and Procedures
Good Manufacturing Practices
Cleaning Procedures
HACCP
Bio security and Food Defence
Product Quality
Chemical Control
Hazard Communication
Blood borne Pathogen
Emergency Preparedness
Employee Safety
Safety Regulatory Requirements/Quality Regulatory Requirements
The Food Safety Team should receive extra training:
nternal Audit Training (Conducted in Step Seven)
HACCP Training
Remember all food handlers should receive Basic Food Hygiene
Training
128
Project Plan
The Steering Group use the Excel Project Plan developed by Senior Management as a step by step guide to
implementing the Food Safety Management System.
129
Step Seven: InternaI Auditing Training & CheckIists
nternal Auditor Training - An interactive and illustrated nternal Audit
training presentation to train your nternal Audit procedure.
14u
The senior management team implement actions to continually improve
the FSMS
Senior Management should implement actions to improve the Food
Safety Management System. This will normally be as outputs from the
Management Review:

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88C lood SafeLy ManagemenL SysLem lmplemenLaLlon Workbook

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