Layers of 3

The USDA's HACCP (Hazard Analysis Critical Control Point) system identifies a layered review of critical control points (Monitor, Direct Observation and Pre-Shipment Review) that can be applied to any crucial quality or food safety element.  The fact is that no matter how confident you are in sustaining a successful process, there is vulnerability for any human/process through error.  People/Processes are not perfect resulting in mistakes that can be costly if not caught/corrected before product ships.

3 layers (the “Who”):

1.  Monitor – this is the person or system that collects the data.

2.  Verifier – this is the person or system that observes the monitoring of the process/reviews the data collected to ensure that it is done properly and that the correct actions are taken when non-compliant data occurs per the written procedure/specification.

3.  Final Review – this is the person or system that assures proper containment of product and preventative measures occurred per procedure/specification prior to the shipment of product to the customer.

The Structure (the “What”, “How” and “Frequency”):

1. Monitoring Procedures - what is being monitored/what are the limits, how monitoring will occur, and the frequency of monitoring.

2. Corrective Actions/Preventative Measures - how will the repeat of failures be eliminated.  Corrective actions are the actions immediately taken to contain the incident/product and Preventative Measures are those taken to eliminate or reduce the likelihood that a failure occurs again.

3. Verification Procedures - regular verification that the system is functioning correctly and that the critical quality/food safety elements are being met.

Final points:

1.  Maintaining accurate records and documentation is also important as this documentation will be verified by government officials, auditors and customers to ensure that the food produced is safe and meets the required specifications.

2.  The data collected can be used to understand trends that are beneficial in continuous improvement initiatives.  A layered review helps assure that the data collected is accurate, which if inaccurate can create false assumptions about a process. Becoming stagnant and ignoring trends can not only allow for loss of future business but also cause producers to lose their edge as the gold standard supplier of products for their customers.

3.  All pertinent team members in the facility should be trained prior to performing the above roles, and at least annually ongoing to ensure that they know and understand how what they do plays an important part in the production of safe, high quality food products.