An Indispensable Quality Assurance Tool for Dairy Processing Plants.

An Indispensable Quality Assurance Tool for Dairy Processing Plants

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Trained

Personnel

Documented

Procedures

Organize

Data

Correct

Procedures

Analyze

Data

Take Action

Test

Product

Some Key Elements for Product Testing

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Incorporate improved technologies

Document information efficiently

Improve accuracy of the data

•Scan product containers

•Import data from test equipment

Goals of a Quality Management System – page 24

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Reduce the cost of the operations

Utilize the lab data easily to improve operations.

•Less time generating reports & graphs

•More time taking action

Goals of a Quality Management System – page 24

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Reduce the cost of the operations

Utilize the lab data easily to improve operations.

•Monitor results to maintain them closer to target.

Goals of a Quality Management System – page 24

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Monitor trends……

Easily see that your QMS and actions are improving quality.

•Is the incoming raw milk continually improving?

•Is the EOC flavor on finished product continually improving?

Goals of a Quality Management System – page 25

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…..patterns of a process

•Results indicate possible training issues?

•Results indicate equipment issues?

Goals of a Quality Management System – page 25

Serviced Homogenizing Valve

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…..other patterns

•Easily look at data for other patterns

For example: freezing point details……

Note: Baseline freezing point for average normal raw milk has been accepted to be -.540 HThe freezing point of raw milk has a relatively constant, narrow range, about-.530H to -.566 H

Out of typical range

Freezing Point of Incoming Raw Milk Tankers

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Improve employee morale and sense of accomplishment

Every job performed in the dairy processing plant is important and ultimately affects the quality of the product.

•Thorough, complete and accurate product information is important every step of the way.

Goals of a Quality Management System – page 25

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Traceability

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Improve employee morale and sense of accomplishment

•Retain employees with a clean, organized work area

•And proper tools to perform the job.

•Reduce the amount of binders and clipboards in the lab.

Goals of a Quality Management System – page 25

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Ultimately improve overall quality of the organization

A high quality organization:

#1 The product meets regulatory standards, and has a high degree of quality.

#2 The product produced is manufactured efficiently and in a cost effective manner.

#3 The product is consistent.

#4 There is good employee morale.

#5 The employees have the right tools for the job.

#6 If an issue arises; a thorough, prompt and effective action is taken.

Goals of a Quality Management System – page 25

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If an issue arises (Customer complaint)…

Be able to trace the product through the process

For example: A customer complaint is received on a ½ gallon homogenized milk with the code 4-14. You should be able to find the lab data in seconds.

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Be able to trace the product through the process

For example: Checking on lab results indicates there was a problem with Side B on Filler and the problem was resolved.

If an issue arises (Customer complaint)…

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If an issue arises (Supplier)…

Find by Ingredient and Lot#

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Interpret Line Samples

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Volume Loss

Finished Product

Grams over/under weight spec

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Volume Loss

Incoming Raw Milk Tankers

Manifest amount vs. Plant Scale

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1. Software must be well documented.

2. Protocols and policies must be clearly documented.

3. Records must be indexed and cross referenced to allow easy review, or must be printed and made available.

4. Records must be secure from unauthorized access and changes.

5. When corrections are necessary the old information must be retained, and the person making the correction must be identified and the reason for the change recorded.

6. If records are not available at time of audit, facility will be cited for not having records and will be subjected to penalties.

Records and Reports (SMEDP page 29):Requirements for electronic / computer records:

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Security in a database

Records must be secure

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Improved Technology

Handle large complex databases

Stable and dependable

Interface Capability with equipment

Connect to other databases

Accessible to those who need the information

Require low maintenance

Program changes are made for you

Important Capabilities for a database program

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Important Features for a database program

Easy to use

Graphs with sort options

Reports with sort options

Export data

Import data

Scan barcodes

Strong query function

Track or limit changes

Highlight out of spec

Totals out of spec

Security

Strong Support

Monthly newsletters

(information on new items)

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Direct support (easy to make contact)

Readily available for support

Support knowledgeable

Prompt response to issues and requests

Extensive documentation on program and procedures

Comments and suggestions are valued

Updates are easy to obtain, can update when it is convenient

Support for a database program

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“Because the graphs take so little time to compile, I can easily look at them every day.”

“I like the scanner because it helps the lab save time and it ensures that lab errors are kept to a minimum.”

“It is easy to enter data and easy to retrieve data for multiple uses.”

“….the generated reports have a capability to offer a great amount of detail….”

“I like the customer reports because they save me a great deal of time.”

“My incoming raw milk quality improved, I think QA Studio is fabulous!”

“I couldn’t imagine being without it.”

“We all love QA Studio.”

Proven to be successful

Here is what QA Studio Users Say: