Effectiveness and performance of HACCP-based programs

Integrating the HACCP and SPC for hazard control and process improvement: a case of pharmaceutical industry

Purpose

The purpose of this study is to integrate two well-established frameworks with an aim to reduce the unwanted rejection rate recurring in the drug production process in pharmaceutical industries. The effectiveness of an integrated framework has been demonstrated by a real-time case study in a complex industrial environment, providing a platform for quality tools application in the pharmaceutical industry.

Design/methodology/approach

The hazard analysis and critical control points (HACCP) provided a basic framework for hazard analysis and its blending with statistical process control (SPC) aided in data-driven decision-making. The extensive brainstorming and Pareto analysis helped to identify potential critical-to-quality characteristics followed by SPC, x¯ and R charts, histograms and Cp and Cpk analysis to spot the critical control point. The fishbone diagram led to the extraction of the leading cause behind the identified problem. Then, based on recommended corrective actions, control limits were adjusted and the process was brought into control. Finally, a product-based cost analysis is also performed to illustrate the financial impact resulting from the proposed method’s successful implementation.

Findings

The integrated framework is applied to a drug production process which has a higher rejection rate (3%) because of the non-conformities. Based on Pareto analysis, potential failure causes were classified and prioritised as inappropriate composition (2.54%), packaging (0.35%), out-of-specification (0.069%), equipment failure (0.022%), input materials (0.018%) and miscellaneous (0.002%). It is found that 84% of the total rejection rate is contributed by inappropriate composition. After taking corrective actions, it is observed that the proposed method has helped to reduce the process rejection rate significantly (2.54-0.82%). In the monetary terms, 2.50% decline per unit costs is noted in this case study work. The proposed integrated framework’s success is further motivating other pharmaceutical industries to implement and expand it to other processes.

Originality/value

The case study is an attempt to contribute to the existing literature of quality management in pharmaceutical industries. In particular, it is a novel example to introduce the simple and user-friendly SPC tool into well-established HACCP framework to enhance its effectiveness in hazard identification. The case study results motivate managers to adopt quality techniques for achieving a higher quality standard and operational excellence.

Food Safety Management Systems, Certified Food Protection Managers, and Compliance with Food Safety Practices Associated with the Control of Listeria monocytogenes in Foods at Restaurants

HIGHLIGHTS

Proper cold holding and date marking practices help control Lm growth in foods. Most restaurants had ≥1 instance of improper cold holding. Less than 50% of all cold holding observations were found to be out of compliance. Restaurants in areas requiring date marking of food were more likely to date mark. CFPM did not predict out-of-compliance observations when FSMS effects were considered.

The application of quality tools in effective implementation of HACCP

Purpose

The purpose of this paper is to empirically investigate the quality tool’s impact on the effectiveness of the Hazard Analysis and Critical Control Point (HACCP)-based food safety system and correlation studies between HACCP effectiveness and business performance in food and pharmaceutical industries.

Design/methodology/approach

A total of 116 survey responses of prominent food and pharmaceutical firms are used to fulfil the aim of this study. The principal component analysis (PCA) method was applied to classify quality tools into a finite number of groups. Further, multiple regression methods are employed to investigate the correlation between HACCP effectiveness and firm’s performance indicators.

Findings

Quality tools are classified into three categories on the basis of their application by using the PCA method: quality tools for hazard identification, quality tools for hazard analysis (QTHA) and quality tools for hazard control. The regression analysis revealed that QTHA has a substantial impact on HACCP objectives (hazard identification, hazard assessment and hazard control). Additionally, the results suggest that the successful implementation of HACCP-based food safety system also delivers a direct influence on the operational and financial performance of the food and pharmaceutical industries.

Originality/value

This paper contributes to the existing body of HACCP knowledge by providing a framework supported by an empirical case study. The case study clustered quality tools into three broad categories related to their application of a HACCP project. Study results can guide and motivate managers to use quality tools with the aim of successful implantation of the HACCP-based food safety system, especially in food and pharmaceutical industries.

Challenges in performance of food safety management systems: a case of fish processing companies in Tanzania

This study provides insight for food safety (FS) performance in light of the current performance of core FS management system (FSMS) activities and context riskiness of these systems to identify the opportunities for improvement of the FSMS. A FSMS diagnostic instrument was applied to assess the performance levels of FSMS activities regarding context riskiness and FS performance in 14 fish processing companies in Tanzania. Two clusters (cluster I and II) with average FSMS (level 2) operating under moderate-risk context (score 2) were identified. Overall, cluster I had better (score 3) FS performance than cluster II (score 2 to 3). However, a majority of the fish companies need further improvement of their FSMS and reduction of context riskiness to assure good FS performance. The FSMS activity levels could be improved through hygienic design of equipment and facilities, strict raw material control, proper follow-up of critical control point analysis, developing specific sanitation procedures and company-specific sampling design and measuring plans, independent validation of preventive measures, and establishing comprehensive documentation and record-keeping systems. The risk level of the context could be reduced through automation of production processes (such as filleting, packaging, and sanitation) to restrict people's interference, recruitment of permanent high-skilled technological staff, and setting requirements on product use (storage and distribution conditions) on customers. However, such intervention measures for improvement could be taken in phases, starting with less expensive ones (such as sanitation procedures) that can be implemented in the short term to more expensive interventions (setting up assurance activities) to be adopted in the long term. These measures are essential for fish processing companies to move toward FSMS that are more effective.

A survey on auditing, quality assurance systems and legal frameworks in five selected slaughterhouses in Bulawayo, south-western Zimbabwe

The purpose of this study was to explore the audits, quality assurance (QA) programmes and legal frameworks used in selected abattoirs in Zimbabwe and slaughterhouse workers' perceptions on their effectiveness. Data on slaughterhouse workers was gathered through a self-completed questionnaire and additional information was obtained from slaughterhouse and government records. External auditing was conducted mainly by the Department of Veterinary Public Health with little contribution from third parties. Internal auditing was restricted to export abattoirs. The checklist used on auditing lacked objective assessment criteria and respondents cited several faults in the current audit system. Most respondents (> 50.0%) knew the purposes and benefits of audit and QA inspections. All export abattoirs had QA programmes such as hazard analysis critical control point and ISO 9001 (a standard used to certify businesses' quality management systems) but their implementation varied from minimal to nil. The main regulatory defect observed was lack of requirements for a QA programme. Audit and quality assurance communications to the selected abattoirs revealed a variety of non-compliances with most respondents revealing that corrective actions to audit (84.3%) and quality assurance (92.3%) shortfalls were not done. A high percentage of respondents indicated that training on quality (76.8%) and regulations (69.8%) was critical. Thus, it is imperative that these abattoirs develop a food safety management system comprising of QA programmes, a microbial assessment scheme, regulatory compliance, standard operating procedures, internal and external auditing and training of workers.

Performance of food safety management systems in poultry meat preparation processing plants in relation to Campylobacter spp. contamination

A diagnostic instrument comprising a combined assessment of core control and assurance activities and a microbial assessment instrument were used to measure the performance of current food safety management systems (FSMSs) of two poultry meat preparation companies. The high risk status of the company's contextual factors, i.e., starting from raw materials (poultry carcasses) with possible high numbers and prevalence of pathogens such as Campylobacter spp., requires advanced core control and assurance activities in the FSMS to guarantee food safety. The level of the core FSMS activities differed between the companies, and this difference was reflected in overall microbial quality (mesophilic aerobic count), presence of hygiene indicators (Enterobacteriaceae, Staphylococcus aureus, and Escherichia coli), and contamination with pathogens such as Salmonella, Listeria monocytogenes, and Campylobacter spp. The food safety output expressed as a microbial safety profile was related to the variability in the prevalence and contamination levels of Campylobacter spp. in poultry meat preparations found in a Belgian nationwide study. Although a poultry meat processing company could have an advanced FSMS in place and a good microbial profile (i.e., lower prevalence of pathogens, lower microbial numbers, and less variability in microbial contamination), these positive factors might not guarantee pathogen-free products. Contamination could be attributed to the inability to apply effective interventions to reduce or eliminate pathogens in the production chain of (raw) poultry meat preparations.