Q4 Low Care Billets, Burgers, Grills, Goujons, Wings, Gammon & Tenders

• Product Number

  Select

• Batch Number

• Conducted on

  Date

• Shift who started run

  Select

Product Changeover

• Is this the first product after a clean down?

  Yes

  No

  N/A

• Please answer N/A to the next 3 questions and move to Formax Product Change over

• Is this a standard product change over

  Yes

  No

  N/A

• Time stopped

  Date

• Time restarted

  Date

• Previous product including batch number

• Next product Including batch number

• empty hoppers

  Yes

  No

  N/A

• Why are hoppers not empty?

• ensure belts empty

  Yes

  No

  N/A

• Why are belts not empty?

• ensure all rework stations (including sausage grinder where appropriate) are emptied and cleaned

  Yes

  No

  N/A

• Why are rework stations not clean/empty?

• Standard settings Audit complete MQR1579

  Yes

  No

  N/A

• Why is MQR1579 not complete?

• Shift Manager signed off

  Sign

• Operator who completed the checks

  Select

• Is this a 3hr rinse down?

  Yes

  No

  N/A

• Time stopped

  Date

• Time restarted

  Date

• Previous product including batch number

• Next product Including batch number

• Empty hoppers, belt, mixer and former

  Yes

  No

  N/A

• Why are they not empty?

• Rinse: lines, mixer, former and dry & wet ingredients silo (where applicable)

  Yes

  No

  N/A

• Why have thy not been rinsed?

• Sanitise: lines, mixer, former and dry & wet ingredients silo (where applicable)

  Yes

  No

  N/A

• Why have they not been sanitised?

• ensure all rework stations (including sausage grinder where appropriate) are emptied and cleaned

  Yes

  No

  N/A

• Why are rework stations not clean/empty?

• Standard settings Audit complete MQR1579

  Yes

  No

  N/A

• Why is MQR1579 not complete?

• Operator who completed the checks

  Select

• Shift Manager signed off

  Sign

• Is this a forced clean down after a breakdown?

  Yes

  No

  N/A

• Time stopped?

  Date

• Time restarted

  Date

• Previous product including batch number

• Next product Including batch number

• Empty hoppers, belts, mixer and former put into paste bins and label with mix number raise non-conformance and place in chill hold

• Why has this not been complete?

• Powder silo to be covered and clearly marked with ingredients and batch numbers, if short of silos box powders up and label as above

  Yes

  No

  N/A

• Why have they not been labelled up?

• Standard settings Audit complete MQR1579

  Yes

  No

  N/A

• Why is MQR1579 not complete?

• Operator who completed the checks

  Select

• Shift Manager signed off

  Sign

Formax Product Changeover

• Have breathers, forming plates, spaces and knock outs been prepped and checked according to procedure. Cell leader/ Engineer to sign

  Sign

• Image of MMS showing information on breather plate, forming plate, spacers and knock out cups

  Media

• Breather Plate Actual

  Media

• Forming Plate Actual

  Media

• Spacers Actual

  Media

• Knock Out Cups Actual

  Media

• Standard settings Checked by Operative/Cell leader

  Sign

• Standard settings Checked by QA

  Sign

• Engineer Present for Changeover

  Sign

• Previous product code

  Select

• Does the Breather Plate have the Correct Bow?

  Yes

  No

  N/A

• Have you bowed the plate

  Yes

  No

  N/A

• Is the Forming Plate Straight?

  Yes

  No

  N/A

• shift manager is aware

  Sign

• QA is aware

  Sign

• Engineers are aware

  Sign

• Are Spacers Straight?

  Yes

  No

  N/A

• shift manager is aware

  Sign

• QA is aware

  Sign

• Engineers are aware

  Sign

• Are Knock Out Cups in Good Condition?

  Yes

  No

  N/A

• shift manager is aware

  Sign

• QA is aware

  Sign

• Engineers are aware

  Sign

• Have Infill bolts been torqued down to 10NM?

  Yes

  No

  N/A

• Torque down now complete

  Yes

  No

  N/A

• Can not torque down engineer informed

  Sign

• Is all tooling stored in correct location?

  Yes

  No

  N/A

• Why is it not in the correct location?

• Is pump box rinse required?

  Yes

  No

  N/A

• Have you carried out a controlled stop and left the plungers in the ready position? DO NOT move to the clean position.

  Yes

  No

  N/A

• Have you carried out a controlled stop, and moved plungers to the clean position? Carry out rinse, check and grease the plungers seals prior to moving into ready position.

  Yes

  No

  N/A

• All checks complete Engineer

  Sign

• All checks complete QA

  Sign

• All checks complete Operator

  Sign

Steamer Validation

• Image of MMS or TI showing Process Temperature, Residence/cook Time and Program Number

  Media

• Steamer Temp Reading

  Media

• Steamer Residence/cook Time

  Media

• Steamer Fan Running

  Yes

  No

  N/A

• Shift

  Select

• Operator completing check

  Select

• Date & Time

  Date

• QA sign off

  Sign

• Cook Achieved?

  Yes

  No

  N/A

Mixer Door Seal Inspection

• Date & Time of inspection

  Date

• Operator checking

  Select

• Full seal checked

  Yes

  No

  N/A

• Why has seal check not been carried out?

• Signs of damage or missing parts

  Yes

  No

  N/A

• Job Card Number

• QA informed

  Sign

Sifter Check

• Date & Time of inspection

  Date

• All screws and fixings accounted for during the strip and rebuild?

  Yes

  No

  N/A

• QA in attendance

  Sign

• Foreign bodies found?

  Yes

  No

  N/A

• QA in attendance

  Sign

• Operator checking

  Select

• Has the start of run replaced one of these checks?

  Yes

  No

  N/A
Inspection

• Operator checking Mixer

  Select

• Date & Time of inspection

  Date

• Mixer door - Full seal checked

  Yes

  No

  N/A

• Why?

• Signs of damage or missing parts on Mixer seal?

  Yes

  No

  N/A

• Job Card Number

• QA informed

  Sign

• Operator carrying out sifter check

  Select

• Date & Time of Sifter Inspection?

  Date

• All screws and fixings accounted for during the strip and rebuild?

  Yes

  No

  N/A

• QA in attendance

  Sign

• Foreign bodies found?

  Yes

  No

  N/A

• QA in attendance

  Sign

Mix

• Shift:

  Select

• Time mix started

  Date

• Paste Bin No (Check paste bins, buggies & spec you must report to QA/SM)

• Paste Bin No (Check paste bins, buggies & spec you must report to QA/SM)

• Paste Bin No (Check paste bins, buggies & spec you must report to QA/SM)

• Paste Bin No (Check paste bins, buggies & spec you must report to QA/SM)

• Passed Bincover & FB check Start of mix

  Yes

  No

  N/A

• Have pieces of bin cover/foreign bodies been found?

  Yes

  No

  N/A

• QA in attendance?

  Select

• Top of paste, voids in corners of bin etc. checked?

  Yes

  No

  N/A

• Why has check not been carried out?

• Then top layer of paste scraped away and disposed to ensure clear?

  Yes

  No

  N/A

• Why?

  Yes

  No

  N/A

• QA signature

  Sign

• Passed Bincover & FB check End of mix

  Yes

  No

  N/A

• Have pieces of bin cover/foreign bodies been found?

  Yes

  No

  N/A

• QA in attendance?

  Select

• Top of paste, voids in corners of bin etc. checked?

  Yes

  No

  N/A

• Why has check not been carried out?

• Then top layer of paste scraped away and disposed to ensure clear?

  Yes

  No

  N/A

• Why?

  Yes

  No

  N/A

• QA signature

  Sign

• Confirm Steamer Fan Running

  Yes

  No

  N/A

• Time mix dropped

  Yes

  No

  N/A

• Steamer Temperature Check matches MMS

  Yes

  No

  N/A

• QA notified

• QA Signature

  Sign

• Person Completing Steamer Checks

  Select

• Image of MMS showing Upper weight limit, Target weight and Lower weight limit

  Media

• weight check 1

  Media

• weight check 2

  Media

• weight check 3

  Media

• weight check 4

  Media

• weight check 5

  Media

• Average weight

• Any High Care Issues Raised?

  Yes

  No

  N/A

• Product spec issue?

• Food Safety Issue?

• Quality Issue/Out of Spec?

• QAS number used

• Visual Standards Achieved?

  Yes

  No

  N/A

• All transfer belts in good condition

  Yes

  No

  N/A

• Has MT or Engineer been called?

  Select

• Person Completing/Formax Rotary Weight Checks

  Select

• Amount of Calcium chloride added

  Media

• Person Completing Calcium Chloride Check

  Select

• Shift Manager Check

  Sign

• Has any equipment been damaged during this product run?

  Yes

  No

  N/A

• Please complete following section

• Please move on to completion
ISSUE

• Name of Equipment damaged

• Quantity of equipment damaged

• Removed form plant

  Select

• Reported to

  Select

• Job card number

Cell leader sign off

• Cell leader aware of all damage

  Sign

• Select date

  Date