High Risk GMP Audit Report - 2022

• Site conducted

  Select

• FLF High Risk Dept GMP Audit Report

• 123 Tenants Road, Bulls 4894

• Conducted on

  Date

• Prepared by

Score out of 100

• 100 answer

General

• Personal Hygiene Practices: Correct PPE being worn, uniforms are clean, operators are aware of the donning procedure, all other PPE (hard hats, earm muffs) are cleaned daily or more frequently if required, Staff are not wearing strong perfumes or aftershaves, no false eyelashes , fingernails or nail polish is to be worn in the food processing areas, finger nails are kept clean and short, personal food stored in correct places, locker rooms tidy with personal clothing stored in appropriate manner. (Record all observations, operators and findings over the month)

  Select Compliant Critical NC Major NC Minor NC Not Operational Not Checked Requires Correction

  • Compliant
  • Critical NC
  • Major NC
  • Minor NC
  • Not Operational
  • Not Checked
  • Requires Correction

• Staff Facilities Is outdoor clothing stored separately from protective clothing? Is there dedicated laundry bags for soiled protective clothing? Is all personal food and drink stored in the staff canteen? Are staff facilities maintained clean by the company?

  Select Compliant Critical NC Major NC Minor NC Not Operational Not Checked Requires Correction

  • Compliant
  • Critical NC
  • Major NC
  • Minor NC
  • Not Operational
  • Not Checked
  • Requires Correction

• Personnel entering the plant must go through the sanitary routines for the relevant area they are entering. High Risk Entry When entering the facility, the hygiene procedure is: • Remove excess personal/outdoor clothing, watch and jewellery, and store in locker. • Remove footwear • Wash and sanitise hands • Put on hairnet • Step into the redline/ “sock only” area • Put on factory protective clothing and completely fasten • Step over the barrier onto the “sock only” grid area • Retrieve gumboots from their pegs, put them down off onto the floor area and put them on • Wash hands, dry and apply sanitiser High Risk Exit When exiting the facility, the hygiene procedure is: • Clean gumboots using boot scrub • Remove gumboots and step onto the “sock only” grid area • Put gumboots on to their storage pegs • Step over the barrier onto the “sock only” floor • Wash hands and dry thoroughly • Remove factory protective clothing and hang for later reuse (if visually clean and it is not the end of shift) or deposit in the laundry collection bag (if soiled/end of shift) • Step over barrier into locker area and put on shoes • Remove hair net and dispose in rubbish (end of shift).

  Select Compliant Critical NC Major NC Minor NC Not Operational Not Checked Requires Correction

  • Compliant
  • Critical NC
  • Major NC
  • Minor NC
  • Not Operational
  • Not Checked
  • Requires Correction

• Observations of operators washing hands at any time they become soiled? Observations of operators boots, and other protective clothing being cleaned or replaced when soiled? Cleanable aprons are to be cleaned with hot potable water and chemical and hung at apron storage facilities when not in use?

  Select Compliant Critical NC Major NC Minor NC Not Operational Not Checked Requires Correction

  • Compliant
  • Critical NC
  • Major NC
  • Minor NC
  • Not Operational
  • Not Checked
  • Requires Correction

• Personnel Movement Policy • If a High-Risk operator crosses from HR into LR they may not return to the HR area via the same path. They can only re-enter through the Red Line Entry following its procedure above. Observations? Are all doors that lead directly to the exterior of the facility from processing areas kept closed at all times and / or have a rapid roller operating door? Are all personal wash facilities for use on entry and throughout the processing areas operated by knee, foot or sensor?

  Select Compliant Critical NC Major NC Minor NC Not Operational Not Checked Requires Correction

  • Compliant
  • Critical NC
  • Major NC
  • Minor NC
  • Not Operational
  • Not Checked
  • Requires Correction

• Jewellery Policy Any jewellery noted being worn on the processing floors or packing hall? (Plain wedding band is allowed, and a medic alert bracelet if notified)

  Select Compliant Critical NC Major NC Minor NC Not Operational Not Checked Requires Correction

  • Compliant
  • Critical NC
  • Major NC
  • Minor NC
  • Not Operational
  • Not Checked
  • Requires Correction

• Staff Behaviour & Loose Item Control Any observations of the following within any of the processing or supporting areas? (Provide room, date and time) Spitting, Chewing gum, drinking Smoking is only permitted in the designated area in the amenities area – any observations of this occurring outside the designated areas? (date area and possible operator to be recorded) Any operators noted taking personal items such as sweets, coins, cigarettes, mobile phones and other electronic items into the processing facility? (dates, rooms, times to be recorded)

  Select Compliant Critical NC Major NC Minor NC Not Operational Not Checked Requires Correction

  • Compliant
  • Critical NC
  • Major NC
  • Minor NC
  • Not Operational
  • Not Checked
  • Requires Correction

• Personal Medicines Are staff aware of personal medicine requirements? Are the team leaders aware of anyone required to carry medicines on them? Medical Screening, Sickness & Injury Policy Are staff aware of the requirements pertaining to communicable diseases and illness? Any exposed dressings identified in the processing areas? (Blue-coloured waterproof dressing)

  Select Compliant Critical NC Major NC Minor NC Not Operational Not Checked Requires Correction

  • Compliant
  • Critical NC
  • Major NC
  • Minor NC
  • Not Operational
  • Not Checked
  • Requires Correction

• Personal Medicines Are staff aware of personal medicine requirements? Are the team leaders aware of anyone required to carry medicines on them? Medical Screening, Sickness & Injury Policy Are staff aware of the requirements pertaining to communicable diseases and illness? Any exposed dressings identified in the processing areas? (Blue-coloured waterproof dressing)

  Select Compliant Critical NC Major NC Minor NC Not Operational Not Checked Requires Correction

  • Compliant
  • Critical NC
  • Major NC
  • Minor NC
  • Not Operational
  • Not Checked
  • Requires Correction

• Documentation is completed as required and legible? (randomly check 5 records)

  Select Compliant Critical NC Major NC Minor NC Not Operational Not Checked Requires Correction

  • Compliant
  • Critical NC
  • Major NC
  • Minor NC
  • Not Operational
  • Not Checked
  • Requires Correction

Cleaning and Chemicals

• Cleaning: Status of the routine cleaning - equipment, drains, walls, knives, trolleys, rubbish etc. Is cleaning gear stored in appropriate manner? Is cleaning gear (including boot scrubbers) in good conditions? Is correct procedure for cleaning being followed - nothing on floor being washed, no high pressure spraying near product etc

  Select Compliant Critical NC Major NC Minor NC Not Operational Not Checked Requires Correction

  • Compliant
  • Critical NC
  • Major NC
  • Minor NC
  • Not Operational
  • Not Checked
  • Requires Correction

• Chemicals: Are all chemicals labelled? Are they stored in required manner? Is PPE available at stations. Chem strength in foot bath

  Select Compliant Critical NC Major NC Minor NC Not Operational Not Checked Requires Correction

  • Compliant
  • Critical NC
  • Major NC
  • Minor NC
  • Not Operational
  • Not Checked
  • Requires Correction

• Cross Contamination: Ensure that unintentional cross-contamination is minimised. All the activities have been organised in a way that prevents cross-contamination. Are good practices being followed to minimise condensation (doors closed where they should be, cold water rather than hot where possible)? If condensation is present have/ are appropriate corrective measures being taken to minimise risk - no product under the affected area, wiped and cleaned.

  Select Compliant Critical NC Major NC Minor NC Not Operational Not Checked Requires Correction

  • Compliant
  • Critical NC
  • Major NC
  • Minor NC
  • Not Operational
  • Not Checked
  • Requires Correction

• Waste bins have lids they must be hands-free or keep open the lid during any process.

  Select Compliant Critical NC Major NC Minor NC Not Operational Not Checked Requires Correction

  • Compliant
  • Critical NC
  • Major NC
  • Minor NC
  • Not Operational
  • Not Checked
  • Requires Correction

Dropped meat / Foreign matter control

• Dropped Meat / Items Policy Raw Meat (line 1) Are operators aware of the process for dropped raw meat? Any observations of this occurring during the month? Cooked RTE Meat Are operators aware of the process for dropped RTE meat? Any observations of this occurring during the month? Cooked Meat that is to be Cooked again by the Consumer Are operators aware of the process for dropped cooked meat that is to be cooked by the consumer? Any observations of this occurring during the month? Sealed Packaged Meat Are operators aware of the process for dropped sealed packaged meat? Any observations of this occurring during the month? Dropped Items in High Risk Are operators aware of the process for dropped items in high risk? Any observations of this occurring during the month?

  Select Compliant Critical NC Major NC Minor NC Not Operational Not Checked Requires Correction

  • Compliant
  • Critical NC
  • Major NC
  • Minor NC
  • Not Operational
  • Not Checked
  • Requires Correction

• Foreign Matter Control: Any possible loose items found in processing areas? Photos? Locations? Were all pens in processing a one-piece metal detectable blue type?

  Select Compliant Critical NC Major NC Minor NC Not Operational Not Checked Requires Correction

  • Compliant
  • Critical NC
  • Major NC
  • Minor NC
  • Not Operational
  • Not Checked
  • Requires Correction

• Glass, Hard Plastics and Ceramics Policy Any new glass or hard plastic items that have been introduced to an area? Have the items been added to the R04 register? Are glass breakage kit located in the following area? (slicing department) Are PC, leading hands and or managers aware of the breakage procedure?

  Select Compliant Critical NC Major NC Minor NC Not Operational Not Checked Requires Correction

  • Compliant
  • Critical NC
  • Major NC
  • Minor NC
  • Not Operational
  • Not Checked
  • Requires Correction

• Wood Policy Any wooden pallets identified in areas other than storage areas for goods inward and outward, in Zone 2 Raw Processing and Palletising areas?

  Select Compliant Critical NC Major NC Minor NC Not Operational Not Checked Requires Correction

  • Compliant
  • Critical NC
  • Major NC
  • Minor NC
  • Not Operational
  • Not Checked
  • Requires Correction

• Metal Policy Are all knives used within the processing envelope of a single blade construction, issued and accounted for using F124 High Risk Knife Issue Register? Are the registers up to date and reflect reality? Are all knives accounted for? Are Team leaders and or managers aware of the process if metal is lost during processing? Staplers only found in the administration offices? Staples are allowed in paperwork but staple bales are not allowed in the processing areas. No paper clips or drawing pins found in the factory?

  Select Compliant Critical NC Major NC Minor NC Not Operational Not Checked Requires Correction

  • Compliant
  • Critical NC
  • Major NC
  • Minor NC
  • Not Operational
  • Not Checked
  • Requires Correction

Traceability

• Identification and traceability: Are all bins, racks, trolleys labelled. product properly labelled - check use-by dates, batch ID's, product descriptions etc. Check any HOLD product is labelled appropriately

  Select Compliant Critical NC Major NC Minor NC Not Operational Not Checked Requires Correction

  • Compliant
  • Critical NC
  • Major NC
  • Minor NC
  • Not Operational
  • Not Checked
  • Requires Correction

R&M / Facilities / construction

• Air Quality Is positive air is used in high-risk areas at a noticeable over-pressure so as to reduce the risk of air contamination in these areas? Temperature Control Are rooms used for the assembly of RTE finished products <12°C?

  Select Compliant Critical NC Major NC Minor NC Not Operational Not Checked Requires Correction

  • Compliant
  • Critical NC
  • Major NC
  • Minor NC
  • Not Operational
  • Not Checked
  • Requires Correction

• Construction Materials Any areas or rooms that present a hazard to the product? Is it scheduled to be repaired on the R&M list? Is the plant made of cleanable, plastic/synthetic/resinous coatings that meet appropriate requirements for food construction materials? Food contact surfaces are not : • Metals such as cadmium, copper, lead and their alloys • Dissimilar metals, if their contact with liquid or substances may create harmful chemical and electrolytic action. • Sponge rubber, stone slab, leather fabrics and any other porous materials • Wood • Galvanised metal

  Select Compliant Critical NC Major NC Minor NC Not Operational Not Checked Requires Correction

  • Compliant
  • Critical NC
  • Major NC
  • Minor NC
  • Not Operational
  • Not Checked
  • Requires Correction

• Floors Are high-risk department floors maintained so they are free of cracks, open joints, depressions or other low areas that could accumulate or harbour contamination? Are wet areas adequately drained to prevent pooling of water? Are floor to wall junctions coved if the areas are subject to wet cleaning and constructed to facilitate easy cleaning in dry areas? Any repairs and maintenance to be done not already on smartsheet

  Select Compliant Critical NC Major NC Minor NC Not Operational Not Checked Requires Correction

  • Compliant
  • Critical NC
  • Major NC
  • Minor NC
  • Not Operational
  • Not Checked
  • Requires Correction

• Windows and Doors Are all windows, doors, service hatches and tunnels that provide access to the facility tight fitting and sealed to minimise the risk to the product from dust, vermin and airborne organisms? Any repairs and maintenance to be done not already on smartsheet

  Select Compliant Critical NC Major NC Minor NC Not Operational Not Checked Requires Correction

  • Compliant
  • Critical NC
  • Major NC
  • Minor NC
  • Not Operational
  • Not Checked
  • Requires Correction

• Equipment Is equipment used to prepare, process, cook, cool and package products: • Suitable for the use in which it is employed • Designed for ease of cleaning • In good operating condition Any repairs and maintenance to be done not already on smartsheet

  Select Compliant Critical NC Major NC Minor NC Not Operational Not Checked Requires Correction

  • Compliant
  • Critical NC
  • Major NC
  • Minor NC
  • Not Operational
  • Not Checked
  • Requires Correction

• Is food contact materials come with a declaration that states it is suitable for food contact use? (choose two items and verify each audit)

  Select Compliant Critical NC Major NC Minor NC Not Operational Not Checked Requires Correction

  • Compliant
  • Critical NC
  • Major NC
  • Minor NC
  • Not Operational
  • Not Checked
  • Requires Correction

Pest / Vermin control

• Pest control: No evidence of pest activities, sightings, infestation. Traps and stations are in appropriate locations. Fans operational. Waste is being managed appropriately to minimise pests.

  Select Compliant Critical NC Major NC Minor NC Not Operational Not Checked Requires Correction

  • Compliant
  • Critical NC
  • Major NC
  • Minor NC
  • Not Operational
  • Not Checked
  • Requires Correction

208 Packing

• 208 CCP Line 2 - Metal Detector: checks conducted, test pieces detected and rejected

  Select Compliant Critical NC Major NC Minor NC Not Operational Not Checked Requires Correction

  • Compliant
  • Critical NC
  • Major NC
  • Minor NC
  • Not Operational
  • Not Checked
  • Requires Correction

• 208 CCP Line 3 - Metal Detector: checks conducted, test pieces detected and rejected

  Select Compliant Critical NC Major NC Minor NC Not Operational Not Checked Requires Correction

  • Compliant
  • Critical NC
  • Major NC
  • Minor NC
  • Not Operational
  • Not Checked
  • Requires Correction

207 Line 7 Room (if operating as high risk room)

• 207 Red Line Door: Door is secure, correct procedures being followed.

  Select Compliant Critical NC Major NC Minor NC Not Operational Not Checked Requires Correction

  • Compliant
  • Critical NC
  • Major NC
  • Minor NC
  • Not Operational
  • Not Checked
  • Requires Correction

• 207 CCP Line 07 Metal detector is checked and test pieces are detected and rejected.

  Select Compliant Critical NC Major NC Minor NC Not Operational Not Checked Requires Correction

  • Compliant
  • Critical NC
  • Major NC
  • Minor NC
  • Not Operational
  • Not Checked
  • Requires Correction

213 Oven Unloading

• Are protocols for Oven 2 unloading being followed if applicable? (blitz cook between low and high risk) (temps taken on low risk side and radioed through to high risk)

  Select Compliant Critical NC Major NC Minor NC Not Operational Not Checked Requires Correction

  • Compliant
  • Critical NC
  • Major NC
  • Minor NC
  • Not Operational
  • Not Checked
  • Requires Correction

211 Packing Hall

• 211 Is the process for transferring items in and out of the High Risk Factory being followed eg inspections occurring when due, sanitiser wipes being used as required etc

  Yes

  No

  N/A

• 211 CCP Line 04 Metal detector is checked and test pieces are detected and rejected.

  Select Compliant Critical NC Major NC Minor NC Not Operational Not Checked Requires Correction

  • Compliant
  • Critical NC
  • Major NC
  • Minor NC
  • Not Operational
  • Not Checked
  • Requires Correction

• 211 CCP Line 05 Metal detector is checked and test pieces are detected and rejected.

  Select Compliant Critical NC Major NC Minor NC Not Operational Not Checked Requires Correction

  • Compliant
  • Critical NC
  • Major NC
  • Minor NC
  • Not Operational
  • Not Checked
  • Requires Correction

• Are finished products labelled correctly? as per the PC?

  Select Compliant Critical NC Major NC Minor NC Not Operational Not Checked Requires Correction

  • Compliant
  • Critical NC
  • Major NC
  • Minor NC
  • Not Operational
  • Not Checked
  • Requires Correction

206 LR packing

• 206 CCP Line 01 Metal detector is checked and test pieces are detected and rejected.

  Select Compliant Critical NC Major NC Minor NC Not Operational Not Checked Requires Correction

  • Compliant
  • Critical NC
  • Major NC
  • Minor NC
  • Not Operational
  • Not Checked
  • Requires Correction

• 206 Requirements as above are met

  Select Compliant Critical NC Major NC Minor NC Not Operational Not Checked Requires Correction

  • Compliant
  • Critical NC
  • Major NC
  • Minor NC
  • Not Operational
  • Not Checked
  • Requires Correction

• 206 Labelling requirements are met and correct

  Select Compliant Critical NC Major NC Minor NC Not Operational Not Checked Requires Correction

  • Compliant
  • Critical NC
  • Major NC
  • Minor NC
  • Not Operational
  • Not Checked
  • Requires Correction