food safety & quality excellence journey -...
TRANSCRIPT
PepsiCo Confidential 1
PepsiCo Kolkata Plant
Food Safety & Quality Excellence Journey
PepsiCo Confidential 2
ISO 22K
implemented.
AIB
Unannounced
audit
TPM
Excellence
Award
HACCP
Certification
2006 2007
2008
2005
Plant Startup
OHSAS
18001 Certification
2013
ISO
14001 and
AIB journey started
TPM consistency
award & CII National
Food safety Award
TPM
Kick off
2009 2012
2014
+905 in AIB
Unannounced audit
2004
2015
Kolkata Plant Journey
Center of Excellence
(H&S
Kolkata Plant Journey Journey Towards Excellence
PepsiCo Confidential 3
FSMS
American Institution of Baking
(AIB)
HACCP 2006-2011
ISO 22 K 2012-2015
FSSC 22 K 2016 .. Onwards
Announced GMP inspection
Unannounced GMP inspection
Quality Program
QSHA standard
implementation
Quality
System Health Audit
Food Safety system in PepsiCo
PepsiCo Confidential 4
A brief about AIB Inspection system
NEW SCORING MATRIX <700 – UNSATISFACTORY
700-910 – RECOGNITION OF ACCOMPLISHMENT (With no Unsatisfactory finding)
915-1000- RECOGNITION OF ACHIEVEMENT (With no
serious finding)
PepsiCo Confidential 5
AIB GMP inspection – Announced to Unannounced
PepsiCo Confidential 6
Kolkata Manufacturing Excellence through TPM
Food safety Quality
QM Pillar Approach
Integration of food safety and HACCP guidelines
under QM - pillar. Circle Targets
Identification of Q Component &
Monitoring through JH
Standards Focused Task forces
Plant Quality &
Food safety
KPIs
An engaged culture at plant developed through participation by all from each level… It’s plant’s way of life
Focused approach on Challenging food safety & Quality through QM Pillar approach
Expanding QA
activities till distributor end: Latent
defect control
More focus on
food safety benchmarking
Supporting JH and E&T
to develop process competent operators
PepsiCo Confidential 7
Circle
audits
Circle
audits
Circle
audits
Circle
audits
Monthly
Review
Action plan
Practice
Related
Infrastructure / System
Abnormalities
Corrective Action Plan
Check Reoccurrence
Kaizen
implementation
Maintenance
Prevention
Food Safety Monitoring Tools
PepsiCo Confidential 8
Major challenges
Sustenance of Each Day AIB Day
Training and awareness (Project and regular manpower)
Huge man movement inside the plant due to multiple projects
Biomethanation
Canteen Expansion
Sprinkler project
Septic tank & PM expansion
project
PepsiCo Confidential 9
No Unsatisfactory Condition Due To Pest
•No pest related consumer complaint received till date Regular Spray At Plant Exterior By PCI Operators
Bird netting done for all RM
/Agro / FG docks
Sample Pest Control Spray Log Sheet Daily Rodabox Monitoring Sheet Daily Pest-o-flash monitoring sheet
PepsiCo Confidential 10
After
Second Line Of Defense Prepared to restrict bird and pest During Loading Unloading
Despatch shutter open and entry for bird and other pest
Before
Before
After
Zero bird
entry
incident
No Unsatisfactory Condition Due To Pest
Door Discipline, Receiving Inspection & Cleaning Of Pallets On Daily Basis
No Unsatisfactory Condition Due To Pest
Closed 40 no
of potential
openings for
pest entry
PepsiCo Confidential 11
Daily Tool Box Talk at all project sites
Project Display Boards and physical separation
CCTV cameras &
shoe cleaners at
process entry
Awareness against sources of contamination
PepsiCo Confidential 12
Plant Engagement program on Food safety
Teacher –student model Food safety related OPLs
Slogans & Posters
PepsiCo Confidential 13
Food Safety PEP Talk , OPL Display & Communication
Food Safety PEP Talk With
Operatives During Shift
Communication
Food Safety OPL Display At
Shop Floor. Food Safety OPL Docket
Food Safety PEP Talk With
Casuals During Plant Entry
Classroom Training For
Management Training Validation
Sample Validation Sheet
1. Circle Audit 2. Internal audit 3. External audit 4. Other findings
Monthly review
Gap analysis
Action plan
Class room
training / on job training
Communication/ Pep talk/
OPL/ Displays
Validation by validation team
PepsiCo Confidential 14
Pla t’s E gage e t progra o Food Safety week & Global handwashing day
PepsiCo Confidential 15
QM Pillar & E&T Pillar _ Collaborative drive - OLC
Developing & Uploading Quality & Food safety Modules in OLC
( ON Line Learning Centre ) – Each One Teach One
Quality dockets available
In online learning center
AIB training ppt
HLE ppt
Procedure for potato receiving
Store Frito-Lay way
HACCP module
Storage procedure
Quality videos available In online learning center
Agro sampling Packaging & palletizing Personnel hygiene Trim & pair station
PepsiCo Confidential 16
Daily Self Inspection Review – Each day AIB Day
Abnormality List
Was In Decreasing
Tread Within Very
Short Time
Before After
Daily Review With Management Team During Management Wall Meeting
Per Day AIB Abnormalities,
80
45
20
10
5
25
45
65
85
Ave/Day( WK-1) Ave/Day( WK-2) Ave/Day( WK-3) Ave/Day( WK-4)
No
of
AIB
ab
no
rma
liti
es
Q
PT
PepsiCo Confidential 17
Engagement program- KPL – QM an integral part
Kolkata Premier League – Plnat’s biggest engagement program – QM pillar is an integral
part of this program – It is Learning through Fun , powered by Team Kolkata
Demo on Q- Defect
PepsiCo Confidential 18
Pla t’s Kaize Co fere ce – observes Quality
improvement & Food Safety related Kaizens – R&R
Pratiyogita E kaizen
Q1 2015
Sharing kaizen s related to Safety , Quality & Productivity
KK – Pratiyogita E kaizen
Q2 2015
Sharing kaizen s related to Safety , Quality & Productivity
PepsiCo Confidential 19
Maintenance Kiosk – Tag Management of
Food safety related issues is included
Posting of Tags prior to
sanitation program
Categorization of Red Tag &
White tag
Food safety Tags – priority A
and Tech- support allocated to
sort out issues
Post Boilout Compliance of
Red & White tags are
monitored
QM & PM Pillar
Intervention
Communication during sanitation day
PepsiCo Confidential 20
First plant to clear
Unannounced audit
Highest ever score of +905 in 2015 among all food plants in India
500
550
600
650
700
750
800
850
900
950
1000
2011 2012 2014 2015
815
760
870 905
AIB Score
AIB Score
Result summary
Highest Score in
Unannounced audit
PepsiCo Confidential 21