CONTINUOUS IMPROVEMENT FOR ARGENTINE DAIRY LABORATORIES THROUGH REDELAC
National Institute of Industrial Technology, INTI. National Institute of Industrial Technology, INTI. Dairy Industry Technological Research Centre. INTI LACTEOS. BuenDairy Industry Technological Research Centre. INTI LACTEOS. Buenos Aires.os Aires. Argentina.Argentina.
Roberto CastaRoberto Castaññedaeda
ICAR 37th Annual Meeting – Riga, Latvia (31 May - 4 June, 2010)
DairyDairy Sector in ArgentinaSector in Argentina
2
The argentine dairy complex is an important and dynamic food chain of the argentine economy, because of
the extension and distribution in the territory.
the generation of employment.
and the promotion of regional economies , where big, medium and small enterprises (milk producers and dairy industries) coexist.
ICAR 37th Annual Meeting – Riga, Latvia (31 May - 4 June, 2010)
MilkMilkProductionProduction
Milk production in Argentina: 10 billion liters.11º place in the ranking of milk world producers.2nd place in Latin America.2.3 million dairy cows. Most of them “holando argentina” breed (holstein).95 % of the milk produced belongs to the “Pampeana”Region (800.000 km 2)11.000 dairy farms
Argentina produce also goat, ewe and buffalo milk.
ICAR 37th Annual Meeting – Riga, Latvia (31 May - 4 June, 2010)
Titulo: Arial 32
Argentina – China Food Scienceand Technology Centre
Workshop on Plant and Animal Protein
Buenos Aires, -10-14 May, 2010
3er Congreso Internacional de Lechería Colonia
4ICAR 37th Annual Meeting – Riga, Latvia (31 May - 4 June, 2010)
Dairy Industry.Dairy Industry.
Important rol in the food and beverage sector.
More than 900 dairies of different sizes (9%).Different technologies, from high technology to artisanal equipment. 29.000 employees (10%) work in the dairy sectorTotal income: u$s 3.400 million dollars (13%)Milk destination: cheese (45%), milk powder (24%), fluid milk (19%), others.All dairy products are produced. Exports (2007: 240.000 ton / u$s 715 millions)
ICAR 37th Annual Meeting – Riga, Latvia (31 May - 4 June, 2010)
Buenos Aires, -10-14 May, 2010
3er Congreso Internacional de Lechería Colonia
6ICAR 37th Annual Meeting – Riga, Latvia (31 May - 4 June, 2010)
Laboratories for milk Laboratories for milk quality, physicochemical quality, physicochemical testing, microbiology, testing, microbiology, residues and contaminants, residues and contaminants, sensory evaluation, and sensory evaluation, and othersothers..
INTI LINTI LáácteoscteosDairy Industry Technological Dairy Industry Technological Research CenterResearch Center
2 work places (Buenos 2 work places (Buenos Aires and RafaelaAires and Rafaela))
92 professionals and 92 professionals and technicianstechnicians
ICAR 37th Annual Meeting – Riga, Latvia (31 May - 4 June, 2010)
ICAR 37th Annual Meeting – Riga, Latvia (31 May - 4 June, 2010)
Research and development (new products)Research and development (new products)
Technical assistance to small and medium enterprises Technical assistance to small and medium enterprises (technology, GMP, HACCP; ISO 22.000, (technology, GMP, HACCP; ISO 22.000, eccecc) )
Training courses.Training courses.
Quality assurance to laboratories.Quality assurance to laboratories.
THE REDELAC IS A COMPLETE INTEGRATED SYSTEM:
THE REDELAC THE REDELAC IS A COMPLETE INTEGRATED IS A COMPLETE INTEGRATED SYSTEM: SYSTEM:
Dairy National Reference Laboratory
Dairy National Dairy National Reference LaboratoryReference Laboratory
The first accredited proficiency testingprovider ISO 17043 in Latin AmericaThe first accredited proficiency testingThe first accredited proficiency testingprovider ISO 17043 in Latin Americaprovider ISO 17043 in Latin America
SICECAL, The ArgentineCentralized Calibration System
SICECAL, The ArgentineSICECAL, The ArgentineCentralized Calibration SystemCentralized Calibration System
Technical AssistanceTechnical AssistanceTechnical Assistance
ICAR 37th Annual Meeting – Riga, Latvia (31 May - 4 June, 2010)
ICAR 37th Annual Meeting – Riga, Latvia (31 May - 4 June, 2010)
Centralized calibration.Centralized calibration.
Control of performance of laboratories.Control of performance of laboratories.
Evaluation of results.Evaluation of results.
2009: Is focused on “continuous improvement of milk laboratories”
Proficiency Testing programmes related to raw milk quality:
Monthly raw milk ControlMonthly raw milk ControlInstrumental equipment ControlInstrumental equipment Control
Technical AssistanceTechnical Assistance
ICAR 37th Annual Meeting – Riga, Latvia (31 May - 4 June, 2010)
Analyses under “Monthly Raw Milk Control are:
- Fat content- Total protein- Total solids- Lactose- Ash- Presence of antibiotics- Freezing point- Enumeration of somatic cells- Enumeration of microorganisms at 30ºC
ICAR 37th Annual Meeting – Riga, Latvia (31 May - 4 June, 2010)
1. Survey of PT participants
2. Definition of indicators and quality tools
3. Segmentation
4. Determination of technical assistance required
5. Planning of annual work and proposal of aims
ICAR 37th Annual Meeting – Riga, Latvia (31 May - 4 June, 2010)
6. Technical Assistance
To improve the To improve the performance of performance of dairy dairy laboratorieslaboratories
1. Survey of PT participants
ICAR 37th Annual Meeting – Riga, Latvia (31 May - 4 June, 2010)
Laboratories´s geographicallocation
2. Definition of indicators and quality tools
ICAR 37th Annual Meeting – Riga, Latvia (31 May - 4 June, 2010)
deviation from a requirementdeviation from a requirement
unsatisfactory results of a proficiency testing roundunsatisfactory results of a proficiency testing round
evaluate as nonconforming work (NC).evaluate as nonconforming work (NC).
ICAR 37th Annual Meeting – Riga, Latvia (31 May - 4 June, 2010)
INDEX
1 ratio NC / total tests
2 ratio NC / total participant laboratories
3 ratio NC / each parameters
2. Definition of indicators and quality tools
ICAR 37th Annual Meeting – Riga, Latvia (31 May - 4 June, 2010)
2. Definition of indicators and quality tools
Final reports of each round, where the historical performance for each parameter is includedMonthly table of NC of all laboratoriesAnnual table of NC of each laboratoryMonthly graphic of NC of all the parametersAnnual graphic of NC of each parameterAnnual graphic of Index 1 for each laboratoryIshikawa diagrams for each parameterCheck lists of each parameter
QUALITY TOOLS
ICAR 37th Annual Meeting – Riga, Latvia (31 May - 4 June, 2010)
2. Definition of indicatorsand quality tools
Monthly raw milk control.Monthly raw milk control. Instrumental equipment controlInstrumental equipment control..
ICAR 37th Annual Meeting – Riga, Latvia (31 May - 4 June, 2010)
Monthly table of NC of all laboratories( July 2009)
011111111
8I
00H
01
1G
01111111
7F
2111111111
7E
111
1D
3111111111111
9C
1111111111
8B
00A
NC DIEM
30ºCESCFPALTSTPFCtests NºLaboratory
nameRegistration
NºITEM
%NC
Total tests
NC DIEM 30ºCESCFPALTSTPFC
9,80,025,05,99,10,00,00,022,211,8
12041100042
Total1416171169151817123
Indice 1 = NC / N° de ensayos totales: 0,10Indice 2 = NC/ N° total de laboratorios : 0,57
FC:Fat Content – TP: Total Protein - TS:Total solid – L:lactose – A:ash – FP: Freezing Point – ESC:Enumeration of somatic cells – EM 30ºC: Enumeration de
microorganisms 30ºC – DI: Detection of inhibitors.
Annual table of NonConformities - Laboratory X
Index 1 = NC/Nº total tests: 0,05
5,412,525,0%3000000012
888080888560
11111117Sept
01111111
7Ag
01111111
7July
01111111
7June
2111111111
7May
01111111
7Apr
00March
01111111
7Feb
111111111
7January
NC / monthDIEM 30ºC
ESCFPALTSTPFCtestN°Month
2. Definition of indicators and quality tools
ICAR 37th Annual Meeting – Riga, Latvia (31 May - 4 June, 2010)
Monthly graphic of NC (for all parameters)
%NC for parameter - December 2009(total: 23 labs.)
17,6%
11,8%
6,7%
0,0% 0,0%
27,3%
16,7%
21,1%
14,3%
0,0%5,0%
10,0%15,0%20,0%
25,0%30,0%
FC
Prot
ein
Sol
ids
Lact
ose
Ash
F P
oint
Som
atic
cells M
O30
ºC
Inhi
b
Parameters
%N
C
Annual graphic of NC (for each parameter)
%NC Fat content - 2009(total: 17 labs.)
35,3% 33,3%
12,5% 12,5%
41,2%
23,5%
11,8%
29,4%
11,8%
0,0%
11,8%17,6%
0,0%5,0%
10,0%15,0%
20,0%25,0%30,0%35,0%40,0%45,0%
2. Definition of indicators and quality tools
ICAR 37th Annual Meeting – Riga, Latvia (31 May - 4 June, 2010)
ConcentraciónLibre de N
Vencimiento
Contenido de N
Grado analítico reconocido
Destilada o pureza equivalente
Ensayo en blanco
No conformidad
Recepción y Almacenamiento
Determinación
Temperatura
T recepción
Conservantes Exposición a condiciones adversas
T almacenamiento
Estado
Acido sulfúrico
Vencimiento
Acido clorhídrico
Concentración
Digestión
Ácido sulfúrico debe hervir
TemperaturaPeso muestra
Tiempo
Titulación
Destilación
TemperaturaEspuma
Aspecto digerido
Lecturas
Sol. de NaOH
Sacarosa
Velocidad succón scrubber
Test de recuperados
N
Temperatura de precalentamiento
Agua
Concentración
Limpieza
Libre de NVencimiento
Reactivos
Equipos
Calibración
Mantenimiento
Personal
Competencia
Calificación
Punto final Bureta
Ishikawa diagram: determination of total protein
2. Definition of indicators and quality tools
ICAR 37th Annual Meeting – Riga, Latvia (31 May - 4 June, 2010)
Designed check lists are available as self-control tool
ICAR 37th Annual Meeting – Riga, Latvia (31 May - 4 June, 2010)
3. Segmentation
Using Index 1: ratio NC / total tests
GROUP INDEX 1 (VALUE)1 0,00 – 0,10
2 0,10 – 0,20
3 0,21 – 0,25
4 > 0,25
SIGALEC 0,08 – 0,12 *
* Values found at the moment of survey
4. Determination of technicalassistance required
5 defined groups
ICAR 37th Annual Meeting – Riga, Latvia (31 May - 4 June, 2010)
5. Planning of annual work and proposal of aims
quantity of laboratories
Group Value index 1 dec 08 aim- dec 09
SIGALEC 0,08 - 0,12 4 4
1 0,00 - 0,10 7 7
2 0,11 - 0,20 3 5
3 0,21 -0,25 3 6
4 >0,25 5 0
ICAR 37th Annual Meeting – Riga, Latvia (31 May - 4 June, 2010)
6. Technical Assistance (TA)
NC detected?
Round results
Trenddetected?
Corrective/ Preventive recommendations
System alert
effective actions?
Punctual TA required
Communication with laboratory
Monitoring following rounds
Indicators and quality tools
yes
yes
no
no
no
Continuous monitoringof laboratory performance
yes
ICAR 37th Annual Meeting – Riga, Latvia (31 May - 4 June, 2010)
Results and discussion
Less number of labs. with value of index NLess number of labs. with value of index Nºº1 > 0,211 > 0,21
Some laboratories improve performance Some laboratories improve performance since the system implementationsince the system implementation
Nº NC/ Nº total tests - 2009
0,190,17
0,15
0,13
0,22
0,12
0,100,12
0,19
0,13
0,08
0,14
0,00
0,05
0,10
0,15
0,20
0,25
ener
o
febr
ero
mar
zo
abril
may
o
juni
o
julio
agos
to
sept
iem
bre
octu
bre
novi
embr
e
dici
embr
e
Tendency to decrease NC / total testsTendency to decrease NC / total tests
ICAR 37th Annual Meeting – Riga, Latvia (31 May - 4 June, 2010)
Results and discussion
Annual graphic of NC (for each parameter)
%NC Fat content - 2009(total: 17 labs.)
35,3% 33,3%
12,5% 12,5%
41,2%
23,5%
11,8%
29,4%
11,8%
0,0%
11,8%17,6%
0,0%5,0%
10,0%15,0%
20,0%25,0%30,0%35,0%40,0%45,0%
Decrease of %NC in the parameters with highest value at the starting point
Monthly monitoring raw milk2009
(total: 23 labs.)
79,8%74,6%
84,9% 86,0%92,9%
86,2% 86,3% 91,2% 94,4%
20,2%25,4%
15,1% 14,0%7,1%
13,8% 13,7% 8,8% 5,6%
0%10%20%30%40%50%60%70%80%90%
100%
Fat C
onte
nt
Prot
eins
Solid
s
Lact
ose
Ash
Free
zing
poin
t
Som
atic
cells
MO
30º
C DI
%conformities %NC
Indentification of tests which require more attention
ICAR 37th Annual Meeting – Riga, Latvia (31 May - 4 June, 2010)
Results and discussion
ALARM SYSTEM
CONTINUOUS IMPROVEMENTFOR DAIRY LABS
INTEGRATED SYSTEM REDELAC-SICECAL
consolidation
implementation
National Institute of Industrial Technology, INTI. National Institute of Industrial Technology, INTI. Dairy Industry Technological Research Centre. INTI LACTEOS. BuenDairy Industry Technological Research Centre. INTI LACTEOS. Buenos Aires. os Aires. Argentina.Argentina.