[Practical QA Solutions] Lessons Learned

Starting a new year is a new time and with new opportunities. For many it is a time of different plans and budgets; hopefully with strategic resources to combat some of last year’s challenges. A new year is also a time that one may encounter mergers, acquisitions, new management, downsizing and other career-changing events. A new year is time to reflect on the old year’s events. What are some lessons learned from 2008?

LEARN FROM YOURSELF. When I Googled food safety and quality, I discovered 5,750,000 items in 0.16 seconds. That number is rather mind-boggling, so I Googled food safety, quality and lessons learned. I discovered 99,200 items in 0.22 seconds with some interesting titles. Lessons Learned from Current Food Crisis and Assuring Food Safety in a Globalized Market are just two examples. Although the Internet is a good resource, it can be a detriment. Have you Googled your company name with the word recall? If you or even your industry has had recalls, you can anticipate the result.

Although one can learn from others, the best lessons learned are the personal ones. A wise man once said, “Fool me once, shame on you; fool me twice, shame on me.” Mistakes will be made, systems will encounter expanding markets and recalls will happen. Each one of these incidents is an opportunity for a lesson learned. Most of us recognize the word melamine, a chemical substance not approved for use in food, and the impact it is having in pet and human food.

SALMONELLA SCARES. It appears microorganisms are making a comeback in food. In the 1970s, Salmonella was a serious problem in the pet food industry. In 2008 Salmonella, specifically Schwarzengrund, has become a problem in the pet food industry (found in dry pet food) again. Pets with Salmonella infections may have diarrhea (some bloody), fever and vomiting. Salmonella can cause serious and sometimes fatal infections in young children and those with a weakened immune system. A pet food processing plant was closed last year due to the presence of Salmonella Schwarzengrund. What are some lessons learned in combating microorganisms in a food plant?

LESSONS LEARNED. My first thought is that any food plant needs an assessment (evaluation for vulnerable areas), microorganism monitoring of the environment/ingredients/finished products (is the program adequate for the risks encountered), isolation of raw materials (ingredient cross contamination with finished products), segregation of processes (establishment of a “sterile” zone and beyond) and hold/test of vulnerable products (include “near final” product flavor enhancers). My second thought is the cleaning program (are SSOPs adequate for the risks encountered), moisture control within the environment (no condensation or leaks on ceilings, ledges, walls or windows) and moisture control inside processes (condensation inside bins, coolers or dust collection), cooking temperature/time (are the killing parameters being adhered to) and undesired traffic flow of air (dirty to clean areas), lift trucks (dirty to clean areas) and humans (dirty to clean areas). The establishment of a sterile zone (where the microorganism killing occurs) will have a direct impact on good manufacturing practices, sanitary design, SOPs, SSOPs and the microorganism monitoring program.

CONCLUSION. Don’t assume your plant is in control of microorganisms. You are dealing with contamination you cannot see. Take a verify and validate approach; bring in outside resources to help. Your company must avoid a child sickened with Salmonella poisoning from one of your products. Just think of the instant publicity that occurs in today’s Internet world.

The author is a Certified Professional Instructor and can be reached at odosland@giemedia.com or by calling 816/436-1627.

Auditor's Soapbox
Some government Web sites make an excellent resource. Save the good ones on a favorites list. Having an online resource (or resources) already filtered to your particular interest would be a strength added to your management skills. Having industry, country and global facts with some history at your finger tips can be utilized to your advantage in planning and budget meetings.