FOOD MANUFACTURING OPERATIONS
POLICIES, PROCEDURES, AND STANDARDS MANUAL
PREFACE
Log of changes to the manual
Food HACCP definitions
References
SYSTEM AND OPERATIONS DESCRIPTION
Operation description
Products meet regulatory standards
Organization and job responsibilities
Environment and facilities description
Methods for adequate grounds
maintenance
Plant construction and design
Water supply
Plumbing
Sewage disposal
Toilet facilities for employees
Hand washing facilities
Waste disposal
Facility plan and food flow
Equipment and utensils
Major equipment items
Design, construction and use
Processes and controls
Enclosures
1. Operation description
2. (a-c) USDA- / FDA- / FDA Fisheries-
inspected products
3. Organization chart and job responsibilities
4. Environment surrounding the facility
5. Facility plan and food flow
6. Major equipment items
MANAGEMENT
AMC-HACCP Management
Food safety policy
Control of documents
Management responsibility and commitment
Food safety management plan
Evaluation of unit performance;
management review
Food safety improvement program
Supervisor / Person In Charge (PIC)
Holding subordinates responsible
Product complaints
Foodborne illness complaints and hoaxes
Food security
Management
Human element – staff
Human element – public
Facility
Operations
Food sabotage
Emergencies
F:ppsm-HITM: mfg-ppsm-2008-Mar tofc-3-08
Table of Contents
Recalls 13. Corrective action report
Traceability 14. System capability monthly audit
Enclosures (A) 15. USDA HACCP evaluation criteria
1. Employee-customer report of quality or 16. HACCP reassessment
hazard problem and disposition
Training Program
2. Foodborne illness information form
Training plan
3. Analysis of an alleged foodborne illness
Training for performance mastery
4. Usual incubation / onset period ranges for
New employee training
select foodborne disease
Cross training
QA, QC, and HACCP Team Continuing education and correct procedure
QA, QC reinforcement
Control of non-conformity Employee training records
Facilities, equipment, and procedures Enclosures (C)
MAP (Modified Atmosphere Packaging) 1. Training plan
Thermometer calibration 2. Lesson plan form
Slush ice calibration 3. New employee training record
High-temperature calibration 4. Continuing education training record
Verifying refrigerator temperatures
Sanitizing solutions
Microbiological testing PREREQUISITE PROCESSES (SSOP /
New product formulation and development GMP)
Enclosures (B)
Personal Hygiene
1. Equipment / instrument calibration and
Employee personal hygiene policies
verification log
Individual illness and disease control
2. Refrigerator temperature log
Cuts and abrasions
3. Sanitizing solution verification log
Personal cleanliness
4. Microbiological testing of production plant
Fingernails
food items
Hair restraint
5. Sample identification sheet
Jewelry and hard objects in pockets
6. Microbiological environmental testing
Handkerchiefs and facial tissues
report
Chewing gum, smoking, and eating
7. Product formulation (recipe) change
Gloves
8. Product formulation (recipe) change
How to use gloves
checklist
Disposable gloves
9. New product development project
Heavy-duty gloves
schedule
Hand washing
10. New product / process development
Employee hand washing policies
HACCP Team
Double hand wash
Self-inspection and food hazard control
Single hand wash
checklists
Medicines
HACCP team operations
First aid
Member code of conduct
Hand cuts and abrasions
HACCP team functioning
Contact with blood or body fluids from
Team membership
another person
Team leader
Enclosures (A)
Roles individuals play in groups
Some major areas for HACCP team action Facility and Equipment Cleaning,
Problem solving Sanitation, and Pest Control
HACCP team meeting, report, and Substances used in cleaning and sanitizing;
corrective action storage of toxic materials
Filling the report Cleaning and sanitation GMPs
HACCP team's measures of success Pest control GMPs
Operational improvement Pest control program
HACCP reassessment Enclosures (B)
Enclosures (B) 1. Cleaning and sanitizing schedule and
11. Daily QA checklist pre-operations report
12. HACCP team monthly meeting report 2. Sanitation procedures and standards
rev 3/26/08 12:26 PM print 7/30/08 Table of contents 1
3. Chemicals list and material safety data FOOD PROCESS HACCP (USDA; FDA; FDA APPENDIX
sheets FISH / FISHERIES) HACCP plans
4. Pest control schedule and report HACCP recipes
General
5. Floor plan / bait placement Product specifications
Determination if a production step is a CCP
Validation studies
Facility and Equipment Maintenance Quality control operations
Technical reports
Maintenance plan and schedule, including Methods of verification
equipment calibration Ingredient hazards
Food contact surface equipment construction Food products HACCP control groups
Non-food contact surface equipment Chemical additives
construction Allergies and adverse food reactions
Equipment operation HACCP recipe, group process flow charts, and
Gaskets HACCP plans
Cooling and refrigeration units Physical hazards
Freezers Chemical hazards
Surplus equipment and items for repair Food manufacturing hazard and control rules
Dunnage racks, shelving, pallets, dollies, etc. Unprotected food items
Backflow prevention valves for plumbing Physical (hard foreign) objects
CO2 backflow prevention valves pH
Warewashing equipment Ice
Enclosures (C) Food tasting
1. Preventive maintenance schedule Surface heat blanching
2. Maintenance procedures and standards Food washing
Pasteurization
Supplies
Production process control log
Qualified suppliers
Cooling
Hazard identification of food items
Assembly and packaging
Ingredient specification
Handling
Defect action levels
Labeling
Natural or unavoidable defects at low levels
Finished products
Mixing food
Unused food
Receiving and storage
Use-by date
Receiving
Discards
Storage
Water activity
Adulteration
Shelf life validation
Aflatoxin
Frozen food
Contamination
Refrigeration units
Raw materials and other items
Thawing
Shelf-stable products
Batters, breading, sauces, gravies,
Cold storage products
dressings, and other similar preparations
Dating and use
Metal detection
Single-service articles
Food transport
Finished product storage
Hold program
Shipping
Rework
Enclosures (D)
Returned product
1. Major suppliers of products used in the
Non-human food
operation and their HACCP qualification
Packaging
2. Supplier letter – example
Enclosures
3. Supplier hazard control of items
1. Food products HACCP control groups
4. Cook controls for safe products
2. Five USDA-based food process flows
5. Supplier controls for safe products
3. Quality-assured HACCP recipe
6. Food item allergen analysis
procedures
7. Detailed list of food allergens and food
4. Food control group process flow charts
intolerance
5. Food HACCP plans
8. Ingredient specifications
6. Production schedule
9. Receiving report
7. Production process control log
10. Receiving quality control
8. Cooked product monitoring form
9. Assemble / package production record
10. Product specifications
11. Product disposal record

F:ppsm-HITM: mfg-ppsm-2008-Mar tofc-3-08 rev 3/26/08 12:26 PM print 7/30/08 Table of contents 2