Introduction:......................................................................................................................... 7

The SSQA (Safety Security and Quality Assurance) Concept:.............. 7

About this Manual................................................................................................................... 9

Why SSQA?............................................................................................................................. 10

Differentiating Features of the SSQA System............................................................. 11

Economic Benefits of SSQA............................................................................................... 13

Guiding Principles:................................................................................................................ 14

Compared Considerations................................................................................................. 14

SSQA Program Enrolment and Available Support...................................................... 15

GCSE-FHP SSQA Program Enrolment Steps:.............................................................. 16

Key SSQA implementation and monitoring Roles.......................................................... 16

The Three Levels of SSQA:................................................................................................ 17

Basic...................................................................................................................................... 17

Intermediate......................................................................................................................... 18

Advanced.............................................................................................................................. 18

Table 1: Non-Negotiable Control Objectives/Elements at all Levels.......................... 18

Certification under SSQA.................................................................................................. 19

Section 1: SSQA Foundations..................................................................................... 20

1.1 Before and After the Building Process................................................................... 20

1.2 Organizing for Consumer Protection Success..................................................... 21

1.2.1 Key Company Functions and Responsibilities: (Leave no Duty Undone)....... 21

1.2.2 Road Map for Food Safety and Quality Management Success........................ 22

1.2.3 employing The NODE strategy in system managEment.................................... 23

1.2.4 Responding to Future Challenges and Opportunities......................................... 26

1.3 Management Foundation and Obligation.................................................................. 27

1.3.1 The Commitment Statement and the Operating Philosophy............................. 27

Section 2: SSQA Implementation.............................................................................. 28

2.1 SSQA Step 1 – Establish the Departmental and Personnel Responsibility Structure 28

2.1.1 Departments and Personnel Roles........................................................................ 29

2.1.2 Retain a qualified SSQA Facilitator........................................................................ 29

2.1.2.1 Recommendations:............................................................................................ 29

2.1.2.2 Qualifications:...................................................................................................... 29

2.1.2.3 Technical Background:...................................................................................... 30

2.2 SSQA Step 2 – Establish the product safety and quality management system 30

2.2.1 Production, Product Safety and Quality Management Programs..................... 31

2.2.1.1 Company Commitment to Product safety and Quality................................. 31

2.2.1.2 Responsibility Assignment................................................................................ 31

2.2.1.3 Management Resource Provisions.................................................................. 31

2.2.1.4 Key Personnel Requirements........................................................................... 32

2.2.1.5 Personnel Supervision....................................................................................... 32

2.2.1.6 Science and Technology................................................................................... 32

2.2.1.7 R & D - Product & Process Concepts Development..................................... 33

2.2.1.8 Product Safety and Quality Management....................................................... 34

2.2.1.9 Management of Crises and Continuation of Supply..................................... 34

2.2.1.10 Approval of Incoming Materials...................................................................... 35

2.2.1.11 Food and Packaging Material Approvals...................................................... 35

2.2.1.12 Co-Manufacturing Partners............................................................................. 36

2.2.1.13 Auxiliary Services Approval............................................................................ 36

2.2.1.14 Customer/consumer Communications.......................................................... 37

2.2.1.15 Regulatory Compliance and Commitment................................................... 37

2.2.1.16 Control of Documentation and Records....................................................... 46

2.2.1.17 Product Safety and Quality Systems Review by top Management.......... 47

2.2.2 Product Safety (Hazards Control) Program.......................................................... 47

2.2.2.1 Product Safety Prerequisite programs & Plan............................................... 48

2.2.2.2 Food Safety (HACCP) Review......................................................................... 58

2.2.3 Quality Assurance..................................................................................................... 58

2.2.3.1 Processing Controls........................................................................................... 59

2.2.3.2 Other Process Control Considerations........................................................... 59

2.2.3.3 Statistical Process Control................................................................................ 60

2.2.3.4 Production Line Inspection and Product Testing........................................... 60

2.2.3.5 Post Processing Product Release................................................................... 61

2.2.3.6 Non-conformance Tracking and control.......................................................... 61

2.2.3.7 Correction and Prevention of Non-conformances......................................... 62

2.2.3.8 Rework or Reprocessed Product Control and Tracking............................... 62

2.2.3.9 Management of Allergens and Unique Claim Products............................... 62

2.2.3.10 Inventory Control.............................................................................................. 64

2.2.3.11 Product Packaging, Labels and Product Labelling Controls..................... 64

2.2.3.12 Lot Identification, Traceability and Recall..................................................... 64

2.2.3.13 Product safety and Quality Assurance System Verification...................... 65

2.2.3.14 System Validation............................................................................................. 66

2.2.3.15 System and Product Audits (Internal Audits)...................................................................... 66

2.2.4 Product Defence & Security.................................................................................... 67

2.2.5 Personnel Training.................................................................................................... 68

2.2.5.1 Specialized Training Requirement................................................................... 69

2.2.5.2 Training Adequacy Considerations.................................................................. 69

2.2.5.3 Assessment of Training Effectiveness............................................................ 71

2.2.6 Good Operation Practices (GOPS), Provisions & Programs............................. 71

2.2.6.1 Establishment Location, Design, Construction and Approval..................... 71

2.2.6.2 Maintenance Program........................................................................................ 77

2.2.6.2      Cleaning and Sanitation................................................................................. 79

2.2.6.4 Personnel Hygiene and Welfare...................................................................... 81

2.2.6.5 Utilities (Water, Ice, Steam, Air and Processing Gases).............................. 86

2.2.6.6 Transportation and Storage.............................................................................. 87

2.2.7 Contamination Control.............................................................................................. 91

2.2.7.1 Process and Product Flow................................................................................ 92

2.2.7.2 Personnel Flow................................................................................................... 92

2.2.7.3 Incompatible Material and Equipment Flow................................................... 92

2.2.7.4 Laboratory controls (where present)............................................................... 92

2.2.7.5 Sensitive Product Control Measures............................................................... 93

2.2.7.6 Control of Contamination during Material Conditioning (Thawing or Tempering)     94

2.2.8 Foreign Material Prevention, Detection and Control........................................... 94

2.2.8.1 Foreign Material Prevention.............................................................................. 94

2.2.8.2 Foreign Material Detection................................................................................ 96

2.2.8.3 Control of Foreign Material Incidents.............................................................. 96

2.2.9 Waste Management and Control............................................................................ 96

2.2.9.1 Waste Collection................................................................................................. 96

2.2.9.2 Waste Handling Equipment and Areas........................................................... 96

2.2.9.3 Waste Disposal and Inspections...................................................................... 97

2.3 SSQA Step 3 –Team Mobilization to Action through Tracking of Exceptional Success – “Team-MATES”........................................................................................................................ 97

2.3.1 Tracking of Exceptional Success............................................................................ 97

2.3.2 SSQA Employee Incentive and Motivation Program........................................... 97

2.3.2.1 Employee Incentive Program:.......................................................................... 97

2.3.2.2 Other Forms of Employee Motivation.............................................................. 99

2.4 SSQA Step 4 – Entire Chain Engagement –“Enti-CE”............................................. 99

2.4.1 Internal Team Development and Engagement.................................................... 99

2.4.2 Selecting and Enlisting the Chain Partners........................................................ 100

2.4.3 Product Failure Liability.......................................................................................... 101

2.4.4 Supply Chain Management................................................................................... 101

2.4.5 Supply Source Management................................................................................. 103

2.4.6 Preventing Fraud and Other Threats................................................................... 103

2.4.7 Fraud Preventing Principles and Approach........................................................ 104

2.5 SSQA Step 5 – Failure Analysis and Control Tracking System – “FACTS”... 106

2.5.1 Supplied Material Failures..................................................................................... 106

2.5.2 Food Safety and Quality Deviation Incidents..................................................... 107

2.5.3 Pre-requisite Program or Personnel Practice Infractions................................. 107

2.5.4 Customer and Regulatory Authorities Feedback............................................... 107

2.5.5 Expanded Scope of Incident Tracking................................................................. 107

2.5.6 Corrective and Preventive ActioN management................................................ 109

2.6 SSQA Step 6 – Continuing Analysis of Realized Effectiveness and Efficiencies – “CARE”................................................................................................................................................. 110

2.6.1 Audit Program and Categories of Audits............................................................. 110

2.6.1.1 Internal Audit categories................................................................................. 111

2.6.1.2 Value-Added Audit System:............................................................................ 112

2.6.1.3 Non-monotonous Checklists........................................................................... 114

2.6.1.4 Hallmarks of SSQA Internal Auditing Techniques...................................... 115

2.6.2 Operation Effectiveness and Efficiency Improvements.................................... 116

2.6.3 Top Management Review Process...................................................................... 117

2.6.4 Cost and Benefit Analysis...................................................................................... 117

2.7 Operation Risk Assessment....................................................................................... 118

2.8 On-going SSQA Management..................................................................................... 121

2.8.1 Partner Selection and Engagement..................................................................... 121

2.8.2 Personnel Training.................................................................................................. 121

2.8.3 Maintenance of Customer and Consumer Satisfaction.................................... 122

2.8.4 Internal and External Quality Incident Correction and Tracking...................... 122

2.8.5 System Assessment (Audits)................................................................................ 122

2.8.6 Maintenance of Access to Regulatory Updates................................................. 122

2.8.9 Paperwork and Records Management................................................................ 123

2.9 Change Management.................................................................................................... 124

Appendices.......................................................................................................................... 126

Appendix 1- The Pledge  (an example of a commitment statement).......................... 126

Appendix 2 - PROCEDURE WRITING GUIDE................................................................. 127

Appendix 3 - FUNCTION / DEPARTMENT REFERENCE............................................. 130

Appendix 4 - Supply Partner Assessment Tool Kit..................................................... 132

Appendix 5 - Sample SSQA Invitation Letter................................................................ 136

Appendix 6 - Cost of Quality - Simple Calculation Chart......................................... 137

Appendix 7 - Paperwork Reduction Guide – The MUD Scale.................................... 137

Appendix 8 - Change Management: Departmental Approval Guide......................... 142

Additional Information Resources.................................................................... 145

References......................................................................................................................... 147

Subject Index.................................................................................................................... 148