CONCLUSIÓN GENERAL DE ENTREVISTAS REALIZADAS EN LA COMPAÑÍA DIXIMANT
1. Inventario – Bodega Hacienda La clemencia
This is a summary of changes in Version 5 from Version 4. Changes that affect the context of a Clause or WGLL have only been included in the Appendix. Spelling mistakes, correction to grammar, change in word (e.g. should to must) etc are excluded from this Appendix. All changes have however, been highlighted in the main body of text, to assist with gap analysis and translation.
Section No. Section Clause Amends
Introduction - Scope The TFMS is applicable to all primary and selected secondary food suppliers to Tesco, with the exception of those that supply whole fresh produce which are audited against the Tesco Produce Packhouse Standard (TPPS) document 414.
1 HACCP 1.4 WGLL (Reworded)
The information is clearly documented within the scope of the study.
1.5 WGLL (Reworded)
The information is clearly documented within the scope of the study. 2 Finished Product Specifications 2.1 Clause (Addition, previously WGLL) – BASE
All TTL specifications are active on or before the point at which products are on sale.
2.8 Clause (Reworded) - BASE
It is the responsibility of site or its respective agent to ensure that where Tesco COP (relevant to product / process) are in place, that they are aware of these and comply with the requirements.
2.9 Clause (Reworded) – BASE
Site technical people or respective agent must be familiar with ‘My Workspace’ and respond appropriately to the designated tasks e.g. out of specification surveillance reports, audits and visits etc.
3 Raw Material & Secondary Site Management
3.6 Clause (Addition) - BASE
The site has a programme in place for reviewing the quality of auditor reports, shadowing and on-going training.
3.11 Clause (Reworded) – BASE
Where meat and meat ingredients must be sourced from Tesco Approved Agricultural Supplier List (203 this must be detailed in the Tesco Technical Library Specification. (Tesco UK only)
Where fresh produce must be sourced from Tesco Approved Sources e.g. Nurture Certificated, this must be detailed in the Tesco Technical Library Specification. (Tesco UK only)
3.12 Clause (Reworded) - BASE
• Date/Lot coding (meets specification and matches COA or COC where
received) 3.13.1 Clause (New) - BASE
Concessions where used, must be based on risk assessment.
Details of the concessions must be fully documented and signed by an authorised person.
WGLL (New)
Trending of number and type of concession may assist with the management of issues (e.g. shelf life, supplier performance etc)
3.16 WGLL (New)
Lockable fire cabinet or secure storage area. 3.21 Clause (Removed) – BASE
Suppliers and primary site auditors must be trained against the Tesco Food Manufacturing Standard before auditing secondary sites and/or contract packers.
4 Packaging None
5 External Areas and Site Security 5.3 WGLL (Removed)
No redundant or stored equipment stored outside.
5.5 Clause (Addition) – BASE
Connecting pipes stored outside must be maintained in a clean condition, stored off the floor and / or capped at the ends.
5.8 WGLL (Addition, previously part of ASPN 5.9.1)
Personnel are encouraged to challenge unknown visitors.
5.9 WGLL (Addition)
5.10 Clause (Removed) - BASE
Dogs and other animals should not be present around the site (see section 26). 6 Design and Construction of Premises 6.6 Clause (Reworded) - BASE
Drains must be accessible for cleaning and fitted with screens or traps to prevent pest entry, odours and debris from blocking drains.
6.13 Clause (Reworded) - BASE
Materials must not be stored directly on the floor or tight against the walls (space is required for pest inspection).
6.14 Clause (Reworded) - BASE
Condensate drainage must be constructed and designed so as to minimise the risks of microbiological contamination.
Drainage pipes must flow to drain and not drip on product, materials, packaging or production equipment.
6.14.1 Clause (Reworded) - MEDIUM
Condensate drainage must have a break near to the floor using a tun-dish to prevent any potential suck back from the drain into the evaporator.
WGLL (Removed) 7 Design and Construction of
Equipment
7.1.1 Clause (New) - MEDIUM
Equipment which is out of service must be suitably identified and stored in a manner that does not pose a risk of injury to persons and / or risk to product. (E.g. left with small parts around the area or in an unhygienic condition).
7.5.1 Clause (Reworded) - BASE
All new food contact materials e.g. work in progress packaging /trays, production belts, chopping boards, food contact utensils etc must comply with legislation for “material and articles intended to come in contact with food" Regulations (EC) 1935/2004 or equivalent; as applied in the country of manufacture.
A written declaration of compliance must be available from the equipment manufacturer.
8 Employee Facilities and Personal Protective Equipment
8.1 Clause (addition) - BASE
8.4.4 Clause (Removed) – ASPN
Locker rooms are warm and have adequate seats/ benches to make changing clothing easy.
8.5.1 Clause (Removed, new guidance in 17.1) – BASE
Legionnaires’ Disease: The control of Legionella bacteria in water systems. Approved Code of Practice and Guidance 2000
(www.hse.gov.uk)
8.6 Clause (Reworded) - BASE
If a contractor is used, their HACCP must be reviewed by the site. 8.7.1 Clause (Addition) - BASE
Procedures in place for illness reporting and return to work (see clauses 31.4 to 31.9)
8.9 Clause (Reworded) - BASE
No hair covering is required unless there is a risk of product contamination (e.g. tray wash operations, transfer point operations)
WGLL (Removed)
A clean company issue hat that is regularly laundered / disposable. 8.9.1 Clause (Reworded) - MEDIUM
Hair covering must be worn and maintained in a good clean condition. • Hair covering must be captive to the site.
• Hair and ears must be fully enclosed by the hair covering. • Beard snoods must be worn to cover beards and moustaches.
• Hair covering must be replaced if removed or changed daily as a minimum.
Where hair covering is worn for religious reasons a risk assessment must be completed and controls in place to manage the risk of product contamination. WGLL (Reworded)
Hairnets are worn under mop caps or washable hair covering. 8.9.2 Clause (Removed)- HIGH
Single use disposable hairnets or mop caps must be worn. No cloth (washable) hair covering is worn without a hairnet.
8.10.2 Clause (Reworded) - HIGH
High risk / high care coats and hard hats must be captive to the area or protected from contamination until transferred into the area.
Protective coats must be visually distinctive from low risk coats and be close fitting at the neck and cuffs.
8.11.1 Clause (Reworded and part removed) - MEDIUM
Protective clothing worn above the knee must be removed in non-production areas (excluding hairnets).
8.11.2 Clause (Addition) – ASPN
All-in-one boiler suits and short jackets are to be phased out. 8.12 Clause (Reworded) - BASE
Frequency of changing protective clothing (including re-usable aprons, gloves and high visibility vests) and disposable items must be defined and verified.
8.12.1 Clause (Removed – already in Base 8.12) - MEDIUM
Frequency of changing protective clothing (including re-usable aprons, gloves, high visibility vests and hard hats) and disposable items must be defined and verified. Clause (Addition)
Aprons and hard hats must be cleaned (or disposable aprons discarded) at defined intervals.
8.12.3 Clause (Addition) – HIGH
Liner gloves must remain captive to the area. 8.13 Clause (Addition, previously WGLL) - BASE
Where external laundry providers are utilised, these must be approved and a specification for the garments (including laundering temperatures and process tolerances) held. Effective laundering by visual assessment of PPE.
8.13.1 Clause (Reworded) - MEDIUM
Home laundering of PPE must not be permitted. Where external laundry services are not available the site must provide an in house service.
8.15 Clause (Reworded) - BASE
Where hand wash facilities are provided, they must have water at a suitable
temperature to encourage effective hand washing, liquid soap (bactericidal and non- scented) and effective hand drying facilities.
WGLL (Removed)
Hand wash water temperature is comfortable, neither too hot or too cold, so as to discourage use.
8.15.2 Clause (Removed) – HIGH
Where additional hand sanitising is in place, it must be suitably controlled Hand washing facilities and /or hand sanitiser must be located close to employee work stations.
8.16 Clause (Reworded) - MEDIUM
Protective clothing must not be worn without hair covering. The procedure must follow the order below:
• Hair covering • Put on footwear
• Wash and / or sanitise hands • Put on coat
8.16.1 Clause (Addition, previously 8.9.1) – HIGH
Where face masks are worn, they should be put on before the final hand wash.
9 Factory Hygiene 9.2 WGLL (Reworded)
E.g. not using high pressure hoses during production or not moving products from the area before commencing any high level cleaning.
9.5 Clause (Removed) – BASE
(e.g. shoulder height and not touching the wall) WGLL (Reworded)
Heat set or resin set bristles in brushes used on food contact surfaces, single blade squeegees in favour of folded blade type as these harbour debris and bacteria. 9.5.1 Clause (Reworded) - MEDIUM
Multiple-use string mops are not permitted.
The use of other types of mop in open food areas must be risk assessed.
Where permitted they must be clean, in a good condition and stored away from product and production processes.
9.6 WGLL (Addition)
Does not conflict with manufacturing colour codes (E.g. red is High Risk but also used for floors in Low Risk)
9.9 Clause (Reworded) - BASE
Cleaning chemicals must be used according to the manufacturers’ instructions including temperature, dilution and contact time. (see clause 29.4)
9.14 Clause (Reworded) - BASE
Sinks for cleaning production equipment must be clearly identified and of suitable size for items being cleaned and must not be used for floor cleaning equipment. 9.16.1 WGLL (Addition)
Trays are stored upside down where necessary to drain. 9.16.2 Clause (Removed) – HIGH
A risk assessment must be in place where this is not carried out. 9.18 Clause (Reworded) - BASE
External waste containers must be fully covered (pest proofed) and segregated. The waste container and area around must be maintained in a clean condition.
WGLL (Addition)
When external waste units are collected the hygiene team is informed so that the area can be cleaned prior to putting new waste unit in place.
10 Personal Hygiene 10.2 WGLL (Addition)
Unsuitable materials
E.g. allergens, pallets, chemicals, etc 10.6 WGLL (New)
Employee number or initials of person written onto the plaster. 10.6.2 Clause (New, previously High) – MEDIUM
There must be plaster reconciliation at the end of the day or shift. 11 Process Controls 11.12 Clause (Addition, previously WGLL) – BASE
Where products are received fresh and subsequently frozen the site must demonstrate the product is suitable for freezing. Details must be included in the raw material specification and the site must demonstrate it was in-life prior to freezing.
12 Traceability 12.1 Clause (Addition) - BASE
provide information relating to receipt of delivery, volume on stock, volume despatched and depots.
WGLL (Addition)
Site has a defined frequency of emptying and cleaning. 12.3.1 Clause (Addition) - BASE
Original documents are submitted where possible.
13 Allergen Control 13.8.1 Clause (Reworded) - ASPN
Products containing allergens must be produced on dedicated equipment, lines or facilities.
13.10 Clause (Reworded) - BASE
Based on risk assessment oils used for the frying of allergenic foods (e.g. shellfish, fish and breaded products) must not be subsequently used for frying products not containing allergens or different allergens.
14 Foreign Body Controls 14.5 WGLL (New)
Condition of glass items on machinery or immediately around/above a process may be checked on a daily start up document. This would be accepted as a daily audit. (see 14.14.1)
Photographic evidence of any existing damage, if immediate repairs not possible. 14.13 Clause (Addition) - BASE
A procedure for disposing of used knives 14.24 Clause (Addition) - BASE
Staples, hole punches, drawing pins etc must not be permitted in production, packing or storage areas.
15 Foreign Body Detection 15.5 Clause (Removed) – BASE
unless authorised by the Tesco Technical Manager. 15.10 Clause (Addition) – BASE
Consecutive leading and trailing checks must be completed in long packs to ensure the reject mechanism can successfully reject, unless the metal detector has a photo electric cell that measures the product prior to passing through the search head. 15.11 Clause (Addition) – BASE
15.24 Clause (Reworded) - BASE
A full investigation must take place to ensure the source of contamination is identified and corrective action plan implemented (and product is dealt with in appropriate manner).
16 Product Inspection and Analysis None
17 Water and Waste Water Management
17.1 Clause (New, previously in WGLL) - BASE
Assessment includes the consideration of Legionella and Cryptosporidium. (also see 8.5.1)
WGLL (New)
For further information on Legionella can be found at -
http://www.hpa.org.uk/Topics/InfectiousDiseases/InfectionsAZ/LegionnairesDisease/ 17.3.3 Clause (Reworded) - BASE
Ice manufactured on site or purchased must be tested for microbiological levels as per other water testing (minimum 6 monthly).
Ice must be handled and stored in a manner that does not pose a risk of contamination.
18 Product Labelling and Coding 18.7 Clause (Removed) – BASE
unless authorised by the Tesco Technical Manager. 18.7.2 Clause (New) - BASE
Re-labelling of products due to printing faults or incorrect labelling must be done in a controlled manner.
Records must be retained. Including details of reasons for re-labelling. Over-labelling is not permitted.
Re-labelling of returned/rejected products may only be carried out with written instruction from the Tesco TM with no break in the chill chain.
18.8 WGLL (Reworded)
18.8.1 Clause (New) - ASPN
A scanner is in place for the verification of barcodes. 18.9.1 Clause (New) - BASE
Where automated coding or label check systems are in place, checks must be carried out at a minimum start and end of product run:
• Single coding and price master data file controlled by the technical department • Password or key card protected system which identifies the person using the
machine
• Prevention system for reversal of Display Until* and Use By codes • Prevention system for incorrect coding at month end.
• Matching system for top and bottom labels, cans and labels or pots and lids etc.
Checks must be in place in the event of a breakdown e.g. power failure. • where this is used on pack.
18.9.2 Clause (Reworded) - ASPN
An automated coding or labelling checking system is in place. 19 Weight, Volume and Count Checks 19.4.2 Clause (Reworded) - BASE
Where ‘In-line’ check-weigh systems are used and an automatic reject system is in place, rejected products must be rejected into a locked bin or other secure method. 19.4.3 Clause (New, previously part of 19.4.2) - ASPN
There must also be a “Bin full” sensor, which stops the line after a pre-set number of items enters the bin or is rejected.
19.9 Clause (Addition) – BASE
All products stating drained weight or glaze levels must be verified at predetermined frequencies to confirm accuracy.
20 Training 20.1 WGLL (New)
Training prior to commencing work in that role and supervised until demonstrably competent. Refresher training given at defined frequency.
A test must be in place to demonstrate understanding of information in the induction package, chemical awareness or procedural training (e.g. CCP).
The correct answers must be discussed with trainees to demonstrate full understanding.
Re-training must be given in areas that are not understood. 20.5.1 Clause (Reworded) - MEDIUM
All food handlers must complete food safety training within 3 months of starting work. e.g. Level 2 Food Hygiene in the UK
WGLL (New)
This may be an in-country course or equivalent in-house training. 20.5.2 Clause (New, previously ASPN) - BASE
Where the induction package has been updated, evidence that all personnel have been trained in any new sections of the package must be available.
20.5.3 Clause (New, previously ASPN) - BASE
There must be a defined time period during which the new starter has a 'training buddy' or extra supervision.
At the end of the initial training period the employees’ competence to do their job must be assessed.
20.8.1 Clause (New, previously ASPN) – BASE
A training matrix must be available showing which employees are trained in which activities. (Matrix must also demonstrate those untrained, in training, trained and able to train others).
20.9.1 Clause (Reworded) - ASPN
All employee appraisals are completed (minimum annually) and records retained.
21 Quality Management System None
22 Product Development None
23 Product Recall/Incident Management 23.6 Clause (Addition, previously ASPN) – BASE
The recall plan must be tested outside of normal office hours, at least every two years.
WGLL (New)
Mock recall is not confused with traceability. The mock recall process is to test effectiveness of procedures.
24 Internal Audits 24.4.1 WGLL (New)
Auditors have a good understanding of TFMS and ideally have attended a TFMS training course.
25 Customer Complaints 25.3 WGLL (Addition)
• Outcome
26 Pest Control 26.7 Clause (Reworded) - BASE
A full and detailed plan indicating positions and type (i.e. toxic/non-toxic) of all baits and monitoring equipment (internal and external), must be kept in the pest control file.
All points must be appropriately sited. Baits must be secured to walls or floors to prevent removal.
Bait boxes must be robust and tamper proof (to prevent removal of bait other than by PCP or pest activity).
Loose/granular toxic baits must not be used in production and storage areas (e.g. poison grain). Gels or blocks must be used.
WGLL (New)
Toxic baits must not be used routinely in storage areas. 26.7.1 Clause (Reworded) - MEDIUM
Toxic baits must not be used in open food processing, storage and associated areas (unless these are situated inside enclosed access panels to service areas / risers). Where an infestation is evident, a derogation (to use toxic baits) is required from the relevant TTM before toxic baits are used.
WGLL (New)
Toxic baits are only used where there is clear evidence of a problem (e.g. actual sightings of rodents or recent droppings)
26.9 WGLL (New)
Consideration is also given to the proofing of window ledges, area above doors, pipework, building structure, redundant buildings etc, to prevent nesting and or roosting birds.
26.14 Clause (Addition) - BASE Break back traps
Where used break back traps must be enclosed, tamper proof and have an indicator to show if the trap has been activated. The design must be as such that it gives a lethal kill.
Break back traps must only be used in production or storage areas with permission of Tesco TM.
Break back traps must be checked at least weekly where they are being used for monitoring activity and daily where they are being used to manage an infestation to observe if they have been activated and reset, where necessary.
This can be done by the PCP or a trained on site person.
If evidence of activity is found the follow up programme must be daily checks until no evidence of activity for 7 days.
WGLL (Reworded)
For example where used in UK manufacturing sites it is a legal requirement that live catch systems such as, sticky boards, are inspected every 12 hrs.
27 Maintenance 27.13 WGLL (New)
Trained in Basic Food Safety and Hygiene 27.14 Clause (Reworded) – BASE
After engineering work (including temporary repairs) has been completed, a system must be in place to assess cleaning requirements prior to use in production.
27.15 WGLL (New)
Lubricating equipment is dedicated to food or non-food lubricants.
28 Calibration None
29 Cleaning Programme 29.7 WGLL (New)
Chemicals meet relevant standards and the cleaning procedure has been fully validated and records retained.
30 Transport 30.2 WGLL (New)
Sites visit or audit the third party facilities where storage or consolidation of finished goods takes place to make sure that they are suitably managed.
30.4 Clause (Reworded) - BASE
Documented maintenance and hygiene procedures and records must be in place for all vehicles (including pipe work e.g. milk tankers).
30.6.1 Clause (New) - BASE
Product is loaded or stacked on pallets in a manner that does not pose a risk to damage or safety in transit.
WGLL (New)
Where product is order picked or consolidated for despatch the site demonstrates good practices (E.g. pallets are of a sensible height, not stacking heavy goods on light, not overhanging pallet etc)
Mixed pallets are interleaved with liners or cardboard to readily identify the different products.
31 Medical Screening 31.4 WGLL (New)
Consideration is given to contractor staff employed by the site (E.g. canteen staff,