Information
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Name:
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Audit Title
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Client / Site
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Position
Course:
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FDF 30111 Certificate III in Food Processing
Unit code(s) and name:
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FDFF2001A Implement the food safety program and procedures
FDFF3001A Monitor the implementation of quality and food safety
FDFOP2064A Provide and apply workplace information
FDOH3001A Contribute to OHS processes
MSAENV272B Participate in environmentally sustainable workplace -
Provide a brief overview of the Candidates workplace role and responsibilities
- Monitoring CCP's
- Completing Quality Paperwork
- Checking Product Quality
- Staff Supervision
- Monitoring OH&S Requirements
- Cleaning & Sanitation
- Basic Routine Maintenance
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Students are observed a number of times during workplace visits. What tasks was the candidate performing at the time of the observations?
- Monitoring CCP's
- Completing Quality Paperwork
- Checking Product Quality
- Staff Supervision
- Monitoring OH&S Requirements
- Cleaning & Sanitation
- Basic Routine Maintenance
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AQF Level Characteristics:
*Demonstrate some relevant theoretical knowledge;
*Apply a range of well-developed skills;
*Apply known solutions to a variety of predictable problems;
*Perform processes that require a range of well developed skills where some discretion and judgement is required
*interpret available information, using discretion and/or judgement
*Take responsibility for own outputs in work and learning
*Take limited responsibility for the output of others (where applicable)
Skills Observation and Critical Questions Checklist
Observe the candidate and check understanding through the associated critical questions:
Observation 1.
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Evidence Guide/Model Answer:
Candidate should follow all OH&S requirements and demonstrate such procedures. -
O.1 Comply with the personal hygiene requirements of the food safety program:
- Wearing hygienic clothing correctly
- Washing and sanitising hands
- Walking through sanitiser foot baths (where applicable)
- No unauthorised jewellery or personal items
- Wear PPE
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Any additional comments:
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Satisfactory?
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Date observed:
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Evidence Guide/Model Answer:
To prevent contaminating food and food handling equipment. Setting a good example to other employees -
Critical Questions (CQs) Why is it important to ensure you wash your hands, wear hairnets correctly and comply with other GMP requirements?
- Prevent contaminating food
- Set a good example
- Prevent contaminating equipment and tools
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Any additional comments:
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Satisfactory?
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Date observed:
Observation 2.
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Evidence Guide/Model Answer:
Must comply with specific work area PPE requirements. (Eye protection etc.) -
O.2 Select, fit and use personal protective clothing and equipment correctly and ensure others in the work group are doing the same.
- Hearing protection
- Safety boots
- Eye goggles
- Apron
- Hairnet
- Gloves
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Any additional comments:
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Satisfactory?
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Date observed:
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Evidence Guide/Model Answer:
PPE is the last resort on the hierarchy of controls. Identify other safety measures. -
Critical Questions (CQs) Does wearing PPE guarantee your safety? Yes/no please explain.
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What other preventative measures keep you safe in the workplace?
- Guarding
- Signage
- Controlled traffic patters
- Emergency stop buttons
- Mechanical aids
- Non slip flooring
- Good housekeeping
- Chemical handling training
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Any additional comments:
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Satisfactory?
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Date observed:
Observation 3.
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Evidence Guide/Model Answer:
• Using correct manual handling techniques or mechanical aids
• Take care in use of chemicals
• Follow machinery/equipment procedures
• Movement around the area complies with the food and safety program -
O.3 Follow all occupational health and safety procedures while conducting duties
- Good housekeeping
- Correct manual handling
- Use Chemicals Safely
- Check signs and guarding
- Prevent tripping hazards
- Practice electrical safety
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Any additional comments:
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Satisfactory?
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Date observed:
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Evidence Guide/Model Answer:
• The candidate should identify a number of potential hazards that are being controlled by a variety of measures (no less than 4). -
Critical Questions (CQs) Can you identify 2 potential safety hazards and 2 environmental hazards in this work area? What are they?
- Spills
- Noise
- Chemicals in the air
- Workplace cleanliness
- Maintain maintenance
- Caught in machinery
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What might go wrong if there were no control measures to prevent this from occurring?
- EPA
- Pollution
- Serious injury or death
- Tripping hazards
- Electrocution
- Machine failure
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Any additional comments:
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Satisfactory?
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Date observed:
Observation 4.
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Evidence Guide/Model Answer:
Routinely or continuously watching the process for inconsistencies, errors or product defects, inspecting packaging and raw materials to ensure they meet quality and food safety requirements, monitoring critical control points in accordance with the HACCP plan, at the same time ensuring that OH&S requirements are followed whilst performing these tasks. -
O.4 Monitor the production process for any food safety, quality and OH&S non-conformances:
- Check for faults
- Monitor product
- Check safety guarding and signage
- Keep watch on quality control
- Complete logbooks
- CCP checks
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Any additional comments:
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Satisfactory?
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Date observed:
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Evidence Guide/Model Answer:
Candidate should explain the company's GMP policies and how they are applied i the work area, demonstrating appropriate communication skills and techniques. Candidates should also explain the companies safe work procedures and any relevant OH&S requirements of the job. -
Critical Questions (CQs) If I was a new employee you were responsible for training, what would you tell me about the food safety and quality requirements for this work area? And what would you tell me about the OH&S requirements for this work area?
- GMP policies
- Toolbox meetings
- PPE
- Safe work procedures
- CCP's
- Safety signage
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Any additional comments:
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Satisfactory?
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Date observed:
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Evidence Guide/Model Answer:
Documented in the food safety and operating procedures/task instructions. Signage. HACCP documents. Induction and training. -
How do you know what the food safety and quality requirements are for your work area?
- Food safety program
- Signs
- HACCP documents
- Induction and training
- Operating procedures
- Task instructions
- Continuous improvements
- Safe work procedures
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Any additional comments:
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Satisfactory?
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Date observed:
Observation 5.
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Evidence Guide/Model Answer:
If any defects are detected, taking action to rectify the situation depending on the job role and level of autonomy. -
O.5 Responding to food safety or quality non-conformance and taking the appropriate corrective and preventative action.
- Remove faulty item from line
- Adjust equipment to prevent further faults
- Notify appropriate personnel
- Shut down machine
- Erect signs or barricades
- Tag out equipment
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Any additional comments:
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Satisfactory?
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Date observed:
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Evidence Guide/Model Answer:
Quality and food safety incidents should be reported to personnel in appropriate positions. -
Critical Questions (CQs) Who do you report quality and food safety incidents to?
- Product supervisor
- Coordinator
- Quality Coordinator
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Any additional comments:
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Satisfactory?
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Date observed:
Observation 6.
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Evidence Guide/Model Answer:
Wearing task related apparel and other appropriate PPE. Following OH&S procedures when handling products and materials. -
O.6 Handle food, materials and equipment hygienically to maintain the quality and safety of the product.
- Wearing food handling gloves
- Washing or sanitising hands
- Wearing hairnets
- Correct clothing
- Correct PPE
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Any additional comments:
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Satisfactory?
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Date observed:
Observation 7.
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Evidence Guide/Model Answer:
Storing tools and equipment in the appropriate area when not in use, cleaning spills and rubbish as you go. -
O.7 Maintain work area and equipment in and orderly and hygienic state, including modelling safe work policies and procedures in own work:
- Put away tools
- Keep equipment clean
- Good housekeeping
- Follow OH&S procedure
- Set a good example
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Any additional comments:
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Satisfactory?
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Date observed:
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Evidence Guide/Model Answer:
• Prevent workplace hazards
• Maintain quality of work -
Critical Questions (CQs) Why is it important to keep the workplace neat and tidy?
- Prevent tripping and slipping
- Minimise contamination
- A better work environment
- Follow OH&S procedures
- Higher food safety standards
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Any additional comments:
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Satisfactory?
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Date observed:
Observation 8.
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Evidence Guide/Model Answer:
Visual inspection, various checks etc. -
O.8 Conduct any required food and safety checks:
- Continuous monitoring
- Weight check
- Seal integrity check
- Temperature check
- Metal detector check
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Any additional comments:
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Satisfactory?
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Date observed:
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Evidence Guide/Model Answer:
Pull down equipment inspecting for signs of wear and tear or areas that have not been properly cleaned. Monitor the performance of other workers in the group to ensure they are cleaning effectively. Look for sources of cross-contamination. Look for dead legs in pipework. Submit all samples taken to the lab for testing.
Problem: The product may be contaminated with a pathogenic organism that may pose a severe health risk to consumers. There are legal limits for some organisms that must be complied with. Product may have to be disposed of and replaced at great cost to the company. -
Critical Questions (CQs) What investigations and actions would you take if some laboratory micro test results from products manufactured on your line were out of specification?
- Check equipment for faults
- Check for dirty areas
- Additional cleaning
- Inspect pipes and hoses
- Look for affected areas
- Take additional samples
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Why might this be a problem? Describe any incidents that may have occurred in the past.
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Any additional comments (describe incidents here please):
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Satisfactory?
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Date observed:
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Examples provided could be:
• Samples
• Various checklists
It is important to regularly check that the process is within specification so that we are not producing unsafe food or food that does not meet the customers expectations. It is also a regulatory, customer and company requirement. -
Describe any OH&S, food safety and quality checks you do or samples you take and explain why this is important.
- OH&S checklists
- Temperate checks
- pH checks
- Date code checks
- Weight checks
- Samples taken throughout production
- Regularly check the quality of the food
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Any additional comments:
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Satisfactory?
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Date observed:
Observation 9.
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Evidence Guide/Model Answer:
Note: Not all candidates will have sampling responsibilities. However, they should still have an understanding of the process involved. Samples must be taken according to company procedure. -
O.9 Take samples (where relevant).
- Take samples with sterile equipment
- Samples must be clearly labelled
- Store samples in appropriate locations
- Follow OH&S procedures
- Maintain records
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Any additional comments:
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Satisfactory?
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Date observed:
Observation 10.
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Evidence Guide/Model Answer:
Waste is clearly identified and placed in appropriate receptacles. Reject product or rework is clearly identified. -
O.10 Handle and disposed of out-of-specification or contaminated food, waste and recycled material in accordance with the requirements of the food safety program (within the scope of responsibility).
- Dispose of waste accordingly
- Waste kept seperate
- Defective products easily identified
- Follow correct procedures
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Any additional comments:
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Satisfactory?
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Date observed:
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Evidence Guide/Model Answer:
Used to identify product in case of recall or other issues. We know which line has made the product. -
Critical Questions (CQs) Why is product and material traceability important?
- So it can be located if there is a problem
- We know which machine made the product
- We know what materials were used
- We know when it was made
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Any additional comments:
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Satisfactory?
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Date observed:
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Evidence Guide/Model Answer:
Depends on the company procedure and the extent of the non-conformance. -
What is the process for dealing with product, raw material or packaging that is out of specification?
- Remove it from the process
- Dispose of product
- Put a hold label on it
- Report to supervisor
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Any additional comments:
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Satisfactory?
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Date observed:
Observation 11.
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Evidence Guide/Model Answer:
Effective use of two way communication including listening and constructive response to feedback, respect and represent the views of others. -
O.11 Communicate effectively and appropriately with others in the work area to give or receive food safety and quality information and OH&S information.
- Ask someone to take a sample
- Asking for/listening to instructions
- Giving instruction to other employees
- Effective use of 2 way communication
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Any additional comments:
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Satisfactory?
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Date observed:
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Evidence Guide/Model Answer:
Identify appropriate personnel and set up a meeting to inform them of issues or problems. -
Critical Questions (CQs) How would you go about organising a meeting to discuss some food safety and quality issues on your line?
- Identify who needs to be there
- Provide details
- Chair meeting
- Take minutes
- Distribute minutes evenly
- Set actions and timelines
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Any additional comments:
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Satisfactory?
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Date observed:
Observation 12.
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Evidence Guide/Model Answer:
Source various workplace documentation and maintain as required. -
O.12 Use/maintain workplace documentation.
- SOP
- Cleaning procedure
- Production schedule
- Product specification
- MSDS
- Product instruction or recipe
- OH&S documentation
- Safe work procedures
- Incident reports
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Any additional comments:
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Satisfactory?
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Date observed:
Observation 13.
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Evidence Guide/Model Answer:
Entering data into a log/computer. The data must be entered to comply with the food safety program. Information must be initialled. -
O.13 Record workplace information in the required format.
- Log sheets
- Report forms
- Updating computer
- Sign off on information you put in
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Any additional comments:
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Satisfactory?
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Date observed:
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Evidence Guide/Model Answer:
As evidence that the required checks have been completed. -
Critical Questions (CQs) What is the purpose of keeping records of food safety and quality checks?
- To show we are up to date with our records
- Can be used to improve products
- Company requirement
- OH&S regulation
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Any additional comments:
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Satisfactory?
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Date observed:
Observation 14.
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Evidence Guide /Model Answer:
The candidate should identify all e-stops, including conveyors and other sub-system equipment. -
O.14 Show me where the emergency stop buttons are on the equipment you are working on.
- Identify all e-stops
- Demonstrated and was in range 0-5
- Demonstrated and was in range 5-10
- Demonstrated and was in range 10-15
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Any additional comments:
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Satisfactory?
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Date observed:
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Evidence Guide/Model Answer:
When employee safety may be compromised or damage to the to equipment may result from faulty parts or products. -
Critical Questions (CQs) When do you need to use an emergy stop?
- When machine needs to be stopped quickly
- Employee might be in danger
- Machine may be damaged
- Defective material may be in use
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Any additional comments:
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Satisfactory?
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Date observed:
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Evidence Guide/Model Answer:
Depending on site LOTO procedure. The purpose of locking out the equipment is to prevent accidental operation while carrying out any of these activities and creating potentially life threatening hazards. -
When and why should a lock-out/tag-out process be used?
- Before maintenence is performed
- Before opening electrical cabinets
- Before removing safety guarding
- Lockouts are to prevent possible hazards that may cause injury or death
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Any additional comments:
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Satisfactory?
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Date observed:
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Evidence Guide/Model Answer:
Candidate should nominate authorised personnel in accordance with site LOTO procedure. -
Who is authorised to perform this procedure in your area?
- Authorised personnel in accordance with LOTO
- Maintenance
- Supervisor
- Operator
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Any additional comments:
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Satisfactory?
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Date observed:
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Evidence Guide/Model Answer:
Depends on level of authority and company procedures. -
What do you do if you see a piece of equipment you need to use has been locked/tagged out?
- Leave it alone
- Contact person whose name is on it
- Notify supervisor
- Follow procedures
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Any additional comments:
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Satisfactory?
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Date observed:
Observation 15.
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Evidence Guide/Model Answer:
Candidate is aware of and working with company environmental guidelines. -
O.15 Work is conducted in accordance with workplace environmental guidelines.
- Recycling policy
- Reusing policy
- Rework policy
- Saving water/energy policies
- Reducing pollution
- Noise reduction techniques
- Spills policy
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Any additional comments:
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Satisfactory?
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Date observed:
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Evidence Guide/Model Answer:
Candidate should follow company procedure and ensure all management and handling of products is to OH&S standards. -
Critical Questions (CQs) How do you manage waste and rework?
- Store in designated locations
- Keep clean and tidy
- Waste and rework clearly identified
- Do not cross-contaminate
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Any additional comments:
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Satisfactory?
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Date observed:
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Evidence Guide/Model Answer:
Candidate is aware of the company environmental guidelines and can identify various procedures. -
What are the company's policies around environmental sustainability and what do you do to follow these?
- Identify recycling procedure
- Identify reusing procedure
- Identify rework procedure
- Identify saving water and energy procedure
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Any additional comments:
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Satisfactory?
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Date observed:
Observation 16.
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Evidence Guide/Model Answer:
Preparing equipment for cleaning and sanitation. Notify relevant personnel of the intention to clean and sanitise (those up or down stream, or in the immediate environment). Cleaning equipment used must comply with the company's GMP policy. Cleaning is to be done in an orderly and logical process from top to bottom, to avoid recontamination, follow the appropriate cleaning procedure. The correct chemicals must be used in the prescribed concentrations. Cleaning of the environment should also be included if it is within the scope of responsibility. -
O.16 Cleaning and sanitation procedures where relevant.
- Preparing equipment for cleaning
- Notify relevant personnel
- Purging lines
- Conducting pre-cleaning rinses
- Operating CIP control panels
- Cleaning equipment complies with GMP policy
- Chemicals used safely with PPE
- Follow appropriate cleaning procedure
- Correct chemicals used
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Any additional comments:
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Satisfactory?
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Date observed:
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Evidence Guide/Model Answer:
Take immediate action if required and report to the person responsible for quality management on the site. -
Critical Questions (CQs) What do you do if you find any pests or signs of pest infestation in the workplace?
- Remove the pest
- Clean the area
- Notify appropriate personnel
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Any additional comments:
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Satisfactory?
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Date observed:
Observation 17.
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Evidence Guide/Model Answer:
Whilst working the student should be able to point out to you and discuss their environmental work practices in reference to the tasks at hand. -
O.17 Environmental work practices:
- Identifies issues
- Complies with regulations
- Reports incidents
- Follows procedures
- Minimises resource damage
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Any additional comments:
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Satisfactory?
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Date observed:
Observation 18.
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Evidence Guide/Model Answer:
Students should demonstrate their ability to accurately perform all required calculations and/or estimations necessary to perform the tasks at hand. Describe the calculations performed and the data used. -
O.18 Carry out calculations and/or estimations:
- Addition
- Subtraction
- Multiplication
- Division
- Estimation
- Product per hour
- Volume of product
- Pallet amounts
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Any additional comments:
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Satisfactory?
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Date observed:
Observation 19.
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Evidence Guide/Model Answer:
Students should step assessor through the procedure for emergency evacuation. This will most likely be a simulation and not a real emergency. -
O.19 Follow emergency procedures in case of a fire. List procedure number in additional comments.
- Viewed procedure
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Any additional comments:
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Satisfactory?
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Date observed:
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Evidence Guide/Model Answer:
Candidate should describe alarms and signals and describe the procedures that follow should these signals or alarms be heard. -
Critical Questions (CQs) Describe the emergency signals and alarms that may occur and what to do if you hear them:
- Described alarms and signals
- Described procedures that follow
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Any additional comments:
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Satisfactory?
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Date observed:
Observation 20.
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Evidence Guide/Model Answer:
Candidate should identify appropriate bandages/dressings -
O.20 Appropriate bandage and dressings.
- Blue bandaids
- First aid kit
- Must wear a glove over bandage
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Any additional comments:
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Satisfactory?
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Date observed:
General Observations - Across Tasks: During the many tasks the student demonstrates, the following should observed across the task.
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Evidence Guide/Model Answer:
Workplace information is required for students to perform their tasks to standard. These skills will be demonstrated across many of the above observations. -
Access and use workplace information, including policies and procedures, food safety program etc.
- Identify requirements
- Locate/source
- Interpret/analyse
- Apply
- Share
- Follow
- Respond to requests
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Any additional comments:
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Satisfactory?
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Date observed:
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Evidence Guide/Model Answer:
Communication is required for students to perform their tasks to standard. These skills will be demonstrated across many of the above observations. -
Communication:
- Listening
- Clarifying
- Questioning
- Seeking advice
- Reading/writing required level for job
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Any additional comments:
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Satisfactory?
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Date observed:
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Evidence Guide/Model Answer:
Student should demonstrate across all tasks their ability to work co-operatively with all team members and respect different cultures in the workplace. -
Work cooperatively Within a culturally diverse workforce.
- Worked cooperatively with team members
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Any additional comments:
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Satisfactory?
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Date observed:
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Evidence Guide/Model Answer:
All tasks observed should be performed within the parameter of each individuals level of responsibility. -
Operates within the parameters of their own work role and responsibilities.
- Tasks performed within level of responsibility
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Any additional comments:
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Satisfactory?
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Date observed:
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Assessors comments/feedback (include any actions required to be taken i the event of 'non-satisfactory' for any part of this assessment.
Final Signoff
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From your observations at the time of the assessment, the candidate's performance was deemed:
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Assessors Name and Signature:
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Student's Name and Signature: