Application of ISO22000, failure mode, and effect analysis (FMEA) cause and effect diagrams and pareto in conjunction with HACCP and risk assessment for processing of pastry products

The Failure Mode and Effect Analysis (FMEA) model has been applied for the risk assessment of pastry processing. A tentative approach of FMEA application to the pastry industry was attempted in conjunction with ISO22000. Preliminary Hazard Analysis was used to analyze and predict the occurring failure modes in a food chain system (pastry processing plant), based on the functions, characteristics, and/or interactions of the ingredients or the processes, upon which the system depends. Critical Control points have been identified and implemented in the cause and effect diagram (also known as Ishikawa, tree diagram, and fishbone diagram). In this work a comparison of ISO22000 analysis with HACCP is carried out over pastry processing and packaging. However, the main emphasis was put on the quantification of risk assessment by determining the Risk Priority Number (RPN) per identified processing hazard. Storage of raw materials and storage of final products at -18°C followed by freezing were the processes identified as the ones with the highest RPN (225, 225, and 144 respectively) and corrective actions were undertaken. Following the application of corrective actions, a second calculation of RPN values was carried out leading to considerably lower values (below the upper acceptable limit of 130). It is noteworthy that the application of Ishikawa (Cause and Effect or Tree diagram) led to converging results thus corroborating the validity of conclusions derived from risk assessment and FMEA. Therefore, the incorporation of FMEA analysis within the ISO22000 system of a pastry processing industry is considered imperative.     

Application of failure mode and effect analysis and cause and effect analysis on processing of ready to eat vegetables – part II

Failure mode and effect analysis (FMEA) model has been applied for the risk assessment of ready to eat vegetables manufacturing. A tentative approach of FMEA application to the ready to eat vegetables industry was attempted in conjunction with cause and effect diagrams. critical control points have been identified and implemented in the cause and effect diagram (also known as Ishikawa, tree diagram and fishbone diagram). The main emphasis was put on the quantification of risk assessment by determining the risk priority number (RPN) per identified processing hazard. Receiving, storage and distribution, packaging and cooling were the processes identified as the ones with the highest RPN (225, 225, 180 and 144 respectively) and corrective actions were undertaken. Following the application of corrective actions, a second calculation of RPN values was carried out leading to considerably lower values (below the upper acceptable limit of 130). It is noteworthy that the application of Ishikawa (cause and effect or tree diagram) led to converging results thus corroborating the validity of conclusions derived from risk assessment and FMEA. Therefore, the incorporation of FMEA and cause and effect analysis within the ISO22000 system of a ready to eat vegetables processing industry is considered imperative.     

Application of failure mode and effect analysis (FMEA) and cause and effect analysis for industrial processing of common octopus (Octopus vulgaris) – Part II

Failure mode and effect analysis (FMEA) model was applied in conjunction with cause-and-effect analysis for the risk assessment of octopus processing ( Octopus vulgaris ). Critical control points were identified and implemented in the cause-and-effect diagram (also known as Ishikawa, tree diagram and fishbone diagram). The main emphasis was put on the quantification of risk assessment by determining the risk priority numbers (RPN) per identified processing hazard. Chemically contaminated product, decomposed raw materials, scombrotoxin presence in the final product, incorrectly labelled product, storage in cans (foreign matter) and defective products, were identified as those with the highest RPN (378, 294, 280, 252, 245 and 144 respectively) and corrective actions were undertaken. Following the application of corrective actions, a second calculation of RPN values was carried out, leading to considerably lower values (below the upper acceptable limit of 130). It is concluded that the incorporation of FMEA analysis within the ISO2200 system of an octopus-processing industry is imperative.     

A comparative presentation of implementation of ISO 22000 versus HACCP and FMEA in a small size Greek factory producing smoked trout: a case study

ISO 22000 is the new standard bound to replace HACCP on issues related to food safety. Although several companies, especially the big ones, have either implemented or are on the point of implementing ISO 22000, there are many others which are rather timid and/or reluctant to implement it. The main reason behind that is the lack of information and the fear that the new standard is too demanding in terms of bureaucratic work. This paper aims at making a comparative presentation of how the two systems can be applied to a small smoked salmon producing company thereby facilitating the emergence of the differences. The main difference is that in ISO 22000 systems like Good Manufacturing Practice and Good Hygiene Practice are prerequisites thus leading to lower number of CCPs. In this case study for example, the number of CCPs dropped from eight (8) in HACCP to four (4) in ISO 22000. Furthermore, the Failure Mode and Effect Analysis was applied to the smoked trout manufacturing process in an attempt to calculate quantitatively the Risk Priority Number (RPN) and to find out whether it can be effectively correlated to ISO 22000 and/or HACCP. RPN was found to be higher than 130 for eight steps, in close agreement with HACCP, thereby indicating that corrective actions will have to be undertaken.     

Application of Failure Mode and Effect Analysis (FMEA), cause and effect analysis, and Pareto diagram in conjunction with HACCP to a corn curl manufacturing plant

The Failure Mode and Effect Analysis (FMEA) model has been applied for the risk assessment of corn curl manufacturing. A tentative approach of FMEA application to the snacks industry was attempted in an effort to exclude the presence of GMOs in the final product. This is of crucial importance both from the ethics and the legislation (Regulations EC 1829/2003; EC 1830/2003; Directive EC 18/2001) point of view. The Preliminary Hazard Analysis and the Fault Tree Analysis were used to analyze and predict the occurring failure modes in a food chain system (corn curls processing plant), based on the functions, characteristics, and/or interactions of the ingredients or the processes, upon which the system depends. Critical Control points have been identified and implemented in the cause and effect diagram (also known as Ishikawa, tree diagram, and the fishbone diagram). Finally, Pareto diagrams were employed towards the optimization of GMOs detection potential of FMEA.     

Application of ISO 22000 and comparison with HACCP on industrial processing of common octopus (Octopus vulgaris) – Part I

Critical control points (CCPs) were identified in the risk assessment of octopus ( Octopus vulgaris ) processing and implemented in the hazard analysis critical control point (HACCP) plan. In the hazard analysis worksheet the different hazards were identified at each processing stage, whereas in the HACCP plan each CCP is identified and accompanied with the relevant significant hazard, critical limit, monitoring of the CCP and corrective actions. In this work comparison of ISO 22000 analysis with HACCP is carried out over octopus processing and packaging. ISO 22000 Analysis Worksheet was employed for determination of some prerequisite programmes (PrPs). Comparison between the two systems has been carried out using the hazard analysis worksheet. The PrPs are the main difference between the two systems. The incorporation of PrPs in the ISO 22000 made the system more flexible as a smaller number of CCPs was introduced.     

Application of failure mode and effect analysis (FMEA), cause and effect analysis and Pareto diagram in conjunction with HACCP to a potato chips manufacturing plant

Failure mode and effect analysis (FMEA) model has been applied for the risk assessment of potato chips manufacturing. A tentative approach of FMEA application to the snacks industry was attempted in order to analyse the critical control points (CCPs) in the processing of potato chips. Preliminary hazard analysis was used to analyse and predict the occurring failure modes in a food chain system (potato processing and potato chips processing plant), based on the functions, characteristics and/or interactions of the ingredients or the processes, upon which the system depends. CCPs have been identified and implemented in the cause and effect diagram (also known as Ishikawa, tree diagram and fishbone diagram). Finally, Pareto diagrams were employed towards the optimisation potential of FMEA.     

Application of failure mode and effect analysis model to foodservice systems operated by chefs in practice and by chefs from a culinary school in Turkey

Failure mode and effect analysis (FMEA) methodology has been applied for the risk assessment of basic foodservice systems operated by the “chefs in practice” and by the “chefs from a culinary school” in Turkey. Firstly, the preliminary hazard analysis was done to predict the potential failure modes in the food flow of basic foodservice systems. Each step in the process, from receiving of raw ingredient to table, was analyzed. The risk priority numbers (RPN) were calculated for each failure mode. The corrective actions were suggested to lower the RPN values below the acceptable limit of 120. The data collected in this study compared to the data from a study carried out with “chefs in practice” about basic food safety issues. The significant difference was observed between “the chefs in practice” and “the chefs with formal culinary education”. Majority of chefs from a culinary school have scored better in many food safety issues, so thus the corrective actions in the FMEA table. The results clearly point out the urgent need for FMEA integration and for food handler education in current foodservice establishments in Turkey.     

Application of failure mode and effect analysis model to foodservice systems operated by chefs in practice and by chefs from a culinary school in Turkey

Failure mode and effect analysis (FMEA) methodology has been applied for the risk assessment of basic foodservice systems operated by the “chefs in practice” and by the “chefs from a culinary school” in Turkey. Firstly, the preliminary hazard analysis was done to predict the potential failure modes in the food flow of basic foodservice systems. Each step in the process, from receiving of raw ingredient to table, was analyzed. The risk priority numbers (RPN) were calculated for each failure mode. The corrective actions were suggested to lower the RPN values below the acceptable limit of 120. The data collected in this study compared to the data from a study carried out with “chefs in practice” about basic food safety issues. The significant difference was observed between “the chefs in practice” and “the chefs with formal culinary education”. Majority of chefs from a culinary school have scored better in many food safety issues, so thus the corrective actions in the FMEA table. The results clearly point out the urgent need for FMEA integration and for food handler education in current foodservice establishments in Turkey.     

Application of ISO22000 and comparison to HACCP for processing of ready to eat vegetables: Part I

Preliminary Hazard Analysis was used to analyse and predict the occurring failure modes in a food chain system (ready to eat vegetables processing plant), in conjunction with ISO22000, the new Food Safety Management System, based on the functions, characteristics and/or interactions of the ingredients or the processes, upon which the system depends. Critical control points (CCPs) have been identified and implemented in the Hazard Analysis Critical Point Control plan. The decision table for CCP determination during processing of ready to eat vegetables is shown and compared with the ISO22000 Analysis Worksheet for determination of the prerequisite programmes. The prerequisite programmes are the main difference between the two systems. The incorporation of PrPs in the ISO22000 made the system more flexible as a smaller number of CCPs was introduced.     

ISO22000体系在大型活动餐饮服务食品安全保障中的应用

摘 要：目的：在大型活动餐饮服务食品安全保障中应用ISO22000 食品安全管理体系, 预防与控制大型活动餐饮服务食品安全保障过程中可能存在的潜在危害。方法：根据 ISO22000 食品安全管理体系标准, 在前提方案（PRP）建立的基础上,对餐饮服务食品安全保障各道工序进行识别和评估,完善了操作性前期方案（OPRP）,确定关键控制点（CCP）,制定了关键限值和控制限值,预防、消除或减少食品安全危害至规定的可接受水平。结果:通过操作性前提方案(OPRP)与HACCP 工作计划,确定6个操作性前期控制点和6个关键控制点（CCP）,构建了餐饮服务食品安全管理体系模式。结论:通过制定操作性前提方案, 将其与HACCP 中的关键控制点结合,将食品安全危害因素降到最低限度, 更好地保障了大型活动期间的餐饮服务食品安全。     

浅谈对ISO22000标准的理解和应用

ISO22000《食品安全管理体系——对整个食品链中组织的要求》是国际标准化组织近期将正式发布的对全球食品安全管理体系的一个统一的标准,实施这一标准可使食品生产加工企业避免因不同国家的不同要求而产生的摩擦,该标准被视为一个集中、统一和整合的食品安全体系,文中提供了该标准基本信息和应用建议。     

ISO22000在保健品维生素C片生产中的应用

目的在保健品维生素C片生产中应用ISO22000食品安全管理体系,预防与控制保健品维生素C片在生产、加工、贮运到销售过程中可能存在的潜在危害。方法根据ISO22000食品安全管理体系标准,采用危害分析与关键控制点(hazard analysis critical control point,HACCP)的质量管理原理,对保健品维生素C片加工中可能的潜在危害进行分析,提出相应的预防措施和监测方法,从人、机、料、法、环5个方面进行分析,并制定相应控制措施。结果确定了原料验收和金属探测2个关键控制点(critical control point,CCP),确定了关键限值和纠偏措施。同时通过制定操作性前提方案(operational prerequisite program,OPRP)与HACCP工作计划,构建了保健品维生素C片的食品安全管理体系模式,符合ISO22000体系。结论通过制定操作性前提方案,将其与HACCP中的关键控制点动态、互补地结合,将食品安全危害因素降到最低限度,更好地保障保健品安全,降低企业管理成本,提升经济收益。     

失效模式与影响分析法评价药品GMP认证缺陷改正效果的探讨

目的探索质量风险管理在药品GMP认证中的应用,使用风险管理工具,指导药品GMP认证技术审评工作。方法用风险管理工具失效模式与影响分析(FMEA)法,评价企业缺陷项目改正的效果。结果和讨论使用FMEA评价整改报告,使药品GMP认证技术审查更系统化、更具科学性。     

ISO22000:2005在速冻青刀豆生产中的应用

介绍了ISO22000在速冻青刀豆生产中的应用,分析了生产过程中的食品安全危害,建立了操作性前提方案和HACCP计划。     

失效模式与影响分析法评价药品GMP认证缺陷改正效果的探讨

目的探索质量风险管理在药品GMP认证中的应用，使用风险管理工具，指导药品GMP认证技术审评工作。方法用风险管理工具失效模式与影响分析（FMEA）法，评价企业缺陷项目改正的效果。结果和讨论使用FMEA评价整改报告，使药品GMP认证技术审查更系统化、更具科学性。     

Food safety management systems performance in African food processing companies: a review of deficiencies and possible improvement strategies

This study seeks to provide insight into current deficiencies in food safety management systems (FSMS) in African food‐processing companies and to identify possible strategies for improvement so as to contribute to African countries' efforts to provide safe food to both local and international markets. This study found that most African food products had high microbiological and chemical contamination levels exceeding the set (legal) limits. Relative to industrialized countries, the study identified various deficiencies at government, sector/branch, retail and company levels which affect performance of FSMS in Africa. For instance, very few companies (except exporting and large companies) have implemented HACCP and ISO 22000:2005. Various measures were proposed to be taken at government (e.g. construction of risk‐based legislative frameworks, strengthening of food safety authorities, recommend use of ISO 22000:2005, and consumers' food safety training), branch/sector (e.g. sector‐specific guidelines and third‐party certification), retail (develop stringent certification standards and impose product specifications) and company levels (improving hygiene, strict raw material control, production process efficacy, and enhancing monitoring systems, assurance activities and supportive administrative structures). By working on those four levels, FSMS of African food‐processing companies could be better designed and tailored towards their production processes and specific needs to ensure food safety. © 2014 Society of Chemical Industry     

ISO 22000在非发酵性豆制品生产中的应用

食品的安全卫生是企业生存的基础。ISO 22000体系作为一种科学有效的管理方法运用于非发酵性豆制品生产企业能发挥积极作用。根据ISO22000食品安全管理体系标准,采用危害分析与关键控制点(hazard analysis critical control point,HACCP)的质量管理原理,从人、机、料、法、环5个方面对非发酵性豆制品生产中潜在的危害进行分析,提出相应的预防措施和监测方法,并制定相应的控制措施。确定原辅料验收、煮浆、配料添加3个关键控制点(油豆腐生产中油炸设为关键控制点),确定了关键限值和纠偏措施。同时通过制定操作性前提方案(operational prerequisite program,OPRP)与HACCP工作计划,构建了非发酵性豆制品的食品安全管理体系模式,符合ISO 22000体系,并运用HACCP原理,根据验证相关管理要素提出相应的管理要求,通过制定操作性前提方案,与HACCP中的关键控制点动态、互补的结合,将食品安全危害因素降到最低限度,更好地保障非发酵性豆制品的安全,降低企业管理成本,提高经济效益。     

推广实施ISO22000保证“添加剂”的安全使用

分析了导致添加剂违规使用问题屡屡发生的多种原因,重点提出推广实施针对食品安全的ISO22000食品安全标准,规范添加剂的使用以保证食品安全。     

ISO22000:2005在冷冻蔬菜生产中的建立与应用研究

依据ISO22000:2005国际标准,建立冷冻蔬菜安全管理体系的危害分析(HA)、操作性前提方案(OPRP)、HACCP计划等,并对标准实施前后产品的生物及物理指标进行分析,为冷冻蔬菜生产企业推广运用ISO22000国际标准提供依据,提高我国出口企业的国际竞争力。