The Certified HACCP Auditor Handbook

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John G. Surak, Steven Wilson
ASQ Quality Press, 2007 - Technology & Engineering - 296 pages
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Contents

Prerequisite Areas for Food Safety
155
TYPES OF PREREQUISITE PROGRAMS
156
Chemical Control
159
Cleaning and Sanitation
163
Sanitary Design and Engineering
164
Preventive Maintenance
165
Trace and Recall
166
Receiving Storage and Shipping Controls
167

Developing a Process Flow Diagram
13
ESTABLISHING THE PREREQUISITE PROGRAM
15
Principle 1Conduct Hazard Analysis
20
Medical Device Hazards
22
Hazard Identification
27
Hazard Evaluation
33
DOCUMENTATION AND ONGOING EFFORTS
36
Principle 2Determine Critical Control Points
37
COMMON SOURCES OF CRITICAL CONTROL POINTS
38
Ingredient Receiving and Handling
39
Distribution
40
Using a Decision Tree
47
Factors Leading to CCP Misidentification
49
DOCUMENTING CRITICAL CONTROL POINTS
50
Principle 3Establish Critical Limits
51
Microbiological
52
Physical
53
Principle 4Establish Monitoring Procedures
54
COLLECTING DATA
55
Monitoring by Observation
56
DETERMINING MONITORING POINTS
57
QUALIFICATIONS OF THE PERSON COLLECTING THE DATA
58
Principle 5Establish Corrective Action Procedures
59
Identifying Causes of Deviations
60
Reevaluating the HACCP Plan
61
Principle 6Establish Verification Procedures
62
Validation
63
Revalidation
65
EXTERNAL REVIEW
66
Principle 7Establish Record Keeping and Documentation Procedures
67
Regulatory Compliance
68
Monitoring Records
69
DESIGNING A RECORD KEEPINGDOCUMENTATION SYSTEM
77
Balanced Approach versus Overkill Approach
82
Computerized versus Manual Records
83
PREVENTING DOCUMENTATION ERRORS
84
HACCP Plan Implementation and Maintenance
86
Product Safety Policies and Objectives
87
Prerequisite Programs
89
HACCP TEAM FORMATION AND TRAINING
91
Team Training
92
PILOT PROJECTSOPERATIONAL QUALIFICATION OF HACCP PLANS
94
COMPANYWIDE HACCP DEPLOYMENT
96
HACCP PLAN MAINTENANCE
97
EXTENDING THE HACCP SYSTEM TO THE SUPPLY CHAIN
99
The HACCP Audit
102
AUDIT FORMAT
104
CONDUCTING THE AUDIT
114
Opening Meeting
115
Collection of Data
117
Analysis of Results
121
Exit Meeting
122
Audit Report Followup and Closeout
123
CLOSURE
126
The HACCP Auditor
128
ETHICS
129
Conflict of Interest
130
Quality Assurance Analytical Tools
132
FLOWCHARTS
133
CAUSEANDEFFECT DIAGRAM
134
HISTOGRAMS
135
CONTROL CHARTS
136
CAPABILITY INDICES
140
CORRECTIVE ACTIONPREVENTIVE ACTION
141
SAMPLING
142
Food Industry in General
148
Biological Hazards
150
Chemical Hazards
153
NEW FOODBORNE DISEASES AND NEW TECHNOLOGIES
154
Supplier Control
168
Water Safety
169
Air Safety
170
Equipment Calibration
171
Audits and Inspection Programs
172
Meat and Poultry
174
HACCP PLAN DEVELOPMENT
175
Hazard Analysis
176
Critical Control Points
178
Monitoring
179
Verification
180
Seafood
182
Biological HazardsViruses
183
Biological HazardsParasites
184
Physical Hazards
185
APPLIED HACCP VERSUS QUALITY
186
Prerequisite Programs
187
Dairy
189
TYPES OF HAZARDS
190
Supplier Control Program
191
Recall Program
192
Fruits and Vegetables
193
Chemical
194
Production Site
195
Field Sanitation
196
Employee Health and Hygiene
197
Retailers
198
Retail and Food Service
200
Hazard Analysis
201
Critical Control Points
202
Critical Limits
203
Verification Procedures
204
MANAGEMENT AND EMPLOYEE TRAINING
205
HACCP Principles in the Design and Manufacture of Medical Devices
208
DESIGN CONTROL
210
MANUFACTURING PROCESSES
212
Quality Requirements
213
APPLICATION OF HACCP TO MEDICAL DEVICES
214
QUALITY SYSTEM INSPECTION TECHNIQUE
217
Hazards in Food
221
Hazards in Medical Devices
224
Validation
225
NACMCF HACCP Guidelines
228
EXECUTIVE SUMMARY
230
DEFINITIONS
231
HACCP PRINCIPLES
232
Prerequisite Programs
233
Developing a HACCP Plan
234
Describe the Food and Its Distribution
235
Determine Critical Control Points CCPs Principle 2
238
Establish Monitoring Procedures Principle 4
239
Establish Corrective Actions Principle 5
241
Establish RecordKeeping and Documentation Procedures Principle 7
243
IMPLEMENTATION AND MAINTENANCE OF THE HACCP PLAN
244
Examples of Common Rerequisite Programs
245
Example of a Flow Diagram for the Production of Frozen Cooked Beef Patties
246
Examples of Questions to Be Considered When Conducting a Hazard Analysis
247
Examples of How the Stages of Hazard Analysis Are Used to Identify and Evaluate Hazards
250
Example I of a CCP Decision Tree
252
Example II of a CCP Decision Tree
253
Examples of Verification Activities
254
Examples of HACCP Records
255
Codex HACCP Guidelines
256
ISO 220002005 Food safety management systemRequirements for any organization in the food chain
263
The ASQ Code of Ethics
266
Body of Knowledge for the Certified HACCP Auditor
268
Glossary
282
Index
286
Copyright

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Page 5 - Identify critical control points. These are points in a food's production — from its raw state through processing and shipping to consumption by the consumer — at which the potential hazard can be controlled or eliminated. Examples are cooking, cooling, packaging, and metal detection.
Page 5 - Establish effective record keeping to document the HACCP system. This would include records of hazards and their control methods, the monitoring of safety requirements and action taken to correct potential problems. Each of these principles must be backed by sound scientific knowledge such as published microbiological studies on time and temperature factors for controlling foodborne pathogens.

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