Foreign matter is an important factor affecting product quality, and it is also one of the factors with the highest proportion of customer feedback and customer complaints. In order to better control foreign matter and improve product quality, here is an introduction to the source of foreign matter and the method of preventing foreign matter.
Source of foreign matter
(1) Classification of foreign bodies:
A Foreign matter:
Metal, glass, gravel, hair, thread wool, paper scraps, wood chips, plastic, paper scraps, glove leather, and other items other than this food.
B Foreign body:
The foreign body of the product itself, all the foreign body of the product itself that cannot be accepted by the customer, such as paste residue, hard fish bones, etc.
(2) Reasons for mixing foreign matter:
The analysis of the mixing of foreign matter from the five aspects of human, machine, material, method and environment usually has the following reasons:
Bringing in processing personnel: As a labor-intensive enterprise, poor management of personnel can cause serious foreign matter incorporation, such as: mixing in hair, wool, glove leather, band-aid, buttons, keys, accessories, cigarette butts, etc.
Damaged and mixed processing equipment and equipment: Damaged or detached processing equipment and equipment can easily cause the mixing of foreign objects. Such as the damage of baskets and knives; bulbs and glass breaks cause glass mixing; welding repairers have welding beans, welding slag, etc., which cause metal mixing.
Poor handling of raw materials: raw materials come from bases, processing sites, etc., and they contain some sundries such as insects, hay, etc., and improper cleaning or incomplete cleaning during processing will cause foreign matter or foreign matter to be mixed in.
The processing method is incorrect, the raw material itself has a lot of foreign matter, and there is no process of sorting and cleaning to remove the foreign matter.
The mixing of foreign matter caused by poor processing environment: such as the mixing of flying insects and flies in the packing box; the mixing of flies and flying insects in the product; the mixing of broken or falling cement blocks on the wall, etc., and the unclean water quality (impurities in the water), inner packaging materials Foreign matter can cause foreign matter to be mixed in and affect the quality of the product.
Measures to prevent foreign matter from entering
The prevention of foreign matter mixing is the primary problem in food processing. The common and frequent control of foreign matter mixing must first analyze the cause of the mixing, and take firm and effective measures to prevent the possibility of foreign matter mixing.
(1) Principles and directions
(1) Strengthen the management of impurities and foreign materials in the raw material warehouse and pre-treatment workshop, such as the waste paper boxes, waste plastic bags, waste cords and labels left after the raw materials are taken out must be cleaned up at any time, kept clean and tidy, and should not be mixed in. One process.
(2) Strengthen the safety and health management of the workshop, conduct timely inspections, and eliminate unsafe health hazards in time. Such as: hunting and killing of flying insects, hair control, latex gloves control, broken tools and equipment control, workshop report paper control, workshop wall paper control, regional and thorough cleaning of lamp tubes, bulb bursts, etc. , Unsafe products must be scrapped.
(3) Strengthen the understanding of the importance of foreign matter, strengthen the management of the control of foreign matter in the workshop in production management, include this item in the important regulations affecting product quality, and mobilize all to control the influx of foreign matter within a safe range .
(2) Specific management of foreign body control:
Non-productive item management
1.1 Supervision and inspection at the entrance of the locker room
a. Before entering the workshop, take the initiative to hand over items that are not related to production to the locker room management personnel (such as: mobile phones, keys, meal cards, etc.) and store them in the non-production item storage area. They are not allowed to be carried or put in casual clothes.
b. Food and beverages are not allowed to be brought into the locker room (such as peanuts, melon seeds, etc.)
c. The locker room management personnel conduct random inspections. For those who fail to meet the above requirements, report to the workshop director for handling.
1.2 Inspection of jewelry
a. It is strictly forbidden to wear jewelry into the dressing room.
b. The headwear, hairpins, etc. worn by individuals entering and leaving the workshop should be checked.
1.3 Button or zipper inspection
a. It is strictly forbidden to wear casual clothes with ornaments (floating and falling off) into the workshop.
b. When workers enter the dressing room, check whether the buttons or zippers on their casual clothes are off or loose. Report the missing buttons in time and keep records in the locker room.
c. Only adhesive buckles are allowed for work clothes, and buttons are strictly prohibited.
1.4 Other non-productive items that must be brought in due to workshop needs
Make a record of the self-inspection of entering and exiting the workshop and the registration of items entering and exiting the workshop.
Staff wear management
2.1 Work clothes hygiene
a. Work clothes must be clean, hygienic, and odor-free.
b. Work clothes are cleaned regularly and kept clean.
c. Work clothes are not damaged and have no heads.
d. The new work clothes must be inspected before they are put on, and the threads on the surface must be removed.
2.2 Work clothes wearing procedure
a. Change slippers → take off casual clothes (check) → change work clothes (check) → wear a mask and inner cap (hair net) → top → work pants → water shoes
b. Wear an apron and sleeves after performing the hand washing and disinfection procedures.
2.3 Wearing requirements
a. The inner cap covers the ears and hair, the inner and outer caps are fastened tightly, and the brim of the cap is close to the face.
b. The mask covers the nose, it is not allowed to take it off casually in the workshop, and it is not allowed to spit in the workshop.
c. All processing personnel wear aprons, and no bad aprons, bad sleeves or bad gloves are allowed in the production process.
d. Do not scribble on aprons, sleeves, and gloves. The name and job number of the processing staff can be written in a certain position.
e. Casual clothes are not allowed to be exposed during processing, and work clothes are strictly prohibited to go out.
Hair control management
3.1 Before putting on work clothes
Self-inspection or mutual inspection of the hair on work clothes and casual clothes. The found hair is attached to the tape and it is strictly forbidden to throw it away. The thread and wool on work clothes, sleeves, and aprons must be thoroughly inspected and removed before entering the workshop. Special personnel are regularly inspected during the production process.
3.2 Wearing procedures
Change slippers → check casual clothes → self-check overalls → wear masks and inner hats (hair nets) → tops → work pants (tops tied in pants) → water shoes
3.3 After dressing neatly
Two people check each other → self-check in the mirror
3.4 Hair inspection after hand washing and disinfection: The hair inspection and paste shall be carried out by a dedicated person.
3.5 During work
a. Set up a special person to check during the work to ensure that the inspection is carried out every hour.
b. Sleeve-rolling is prohibited during work to prevent hair from escaping from the cuffs.
c. The inspectors check out the hairs and collect them in a centralized manner.
3.6 Hair inspection
Head→shoulder→back→front chest→arms and underarms→legs
3.7 The hair sticking tool is a sticking roller or tape (the color of the tape is better to have a large contrast with the color of the product to prevent mixing).
3.8 Replacement of hair sticking equipment
a. In the hair inspection before entering the workshop, replace the hair sticking paper every 4 people inspected.
b. Change the sticky paper according to the situation during processing.
3.9 The staff must wash their hair after haircut, clean up the hair scum, and actively report to the sanitation team inspector before entering the workshop, and accept the inspection by the sanitation team, and then enter the workshop after being qualified.
3.10 Male workers are not allowed to enter the workshop with a long beard
3.11 Encourage and urge processing staff to take a bath and wash their hair twice a week.
Operation management between original, auxiliary and material
4.1 Before use
a. All raw and auxiliary materials must be cleaned of the outer packaging before use.
b. All raw and auxiliary materials that are packaged inside and outside are not allowed to be brought into the processing workshop outside the package.
c. The inner and outer packaging materials are placed separately from the ground.
4.2 When in use
a. Use the first-in first-out principle.
b. Any raw and auxiliary materials should be opened neatly before use to avoid mixing of foreign matter.
Equipment maintenance management
5.1 Count the quantity of tools brought by the maintenance personnel, and record the "Record of Outsiders Entering the Workshop" by the personnel in the dressing room
5.2 The work clothes of maintenance personnel shall be kept hygienic and clean.
5.3 Non-essential tools are prohibited from being brought into the workshop, and the special toolbox prepared by the workshop is kept clean and hygienic at all times.
Note: If the mechanical equipment in the shift is damaged, it is necessary to use an electric welding machine, tie the wires, or dig the ground, replace the lamp tube, etc., which may cause serious product safety hazards. Maintenance projects are strictly prohibited during normal production and must be cleaned up after the shift. Implement.
Glass product management
6.1 Lamp replacement specification
a. It is strictly forbidden to repair or replace the lamp tube during the normal production and processing process. Repairs and replacements should be carried out after no products are available after shift.
b. Replacement procedures (by professionals):
·Remove the waste tube (at least two people on site) → carefully seal to prevent exposure → send it out of the workshop
·New lamp tube → carefully seal → bring it into the workshop for installation → check the firmness of the protective cover → on-site sanitary cleaning
6.2 Workshop glass door and window management
a. All glasses are covered with protective cellophane.
b. The cleaning and management of glass hygiene are implemented to individuals.
c. If the glass on the doors and windows (if there is glass in the workshop) is cracked, organize personnel to replace it after the shift.
d. If there is an emergency in the class that causes glass damage, deal with it as a major problem to ensure product safety.
6.3 Mirrors in the locker room: unified number management, regular inspections and records; if there is an emergency in the class, it will be handled as a major abnormal problem.
6.4 Any glassware is strictly prohibited to be used in the workshop. Special circumstances: such as pressure gauges and thermometers must be equipped with protective facilities for special storage.
Metal products use management
7.1 Control during processing
a. In terms of raw materials: through visual inspection (and magnet adsorption) to ensure that no metal is mixed in the raw materials.
b. Tools, equipment and facilities
·The equipment used is not damaged. Check every shift. Broken appliances are strictly prohibited. If there is any damage during the processing, the damaged tools and instruments shall be discontinued from use, and the products shall be stored separately during this period of time and shall be processed after evaluation.
·Where there are welding on appliances, tables, facilities, etc., the welding beans on the surface must be removed before use to ensure that there are no welding cracks during the production process.
·Equipment safety and sanitation control, such as the small screws used in some machines, the number must be checked when replacing, confirm whether there are missing, and report in time.
c. Equipment and instruments for control: metal detectors are added for detection and monitoring during packaging.
Paper usage management
8.1 Check the workers entering the workshop before shift every day, and bring waste paper into the workshop when they are not allowed to work.
8.2 Implement quantity management of the reports used in the processing process, do not bring redundant reports into the workshop, and ensure that the reports brought into the workshop are not damaged.
8.3 Check the filled-in report form regularly during the processing process, and find the damage immediately. If it is not found, the products produced within the time period will be stored separately and processed after evaluation.
8.4 When the processing personnel in the shift leave the workshop in an accident, use the company's unified leave notice, and it is strictly forbidden to scribble without permission, causing unnecessary waste paper.
8.5 Packaging products: When the product is inverted, the carton must be separated from the product and packaging surface to prevent paper scraps from being mixed into the finished product.
8.6 When leaving the workshop after shift, check the report for damage. If the report is not found to be damaged, the product shall be stored separately during the last inspection period and processed after evaluation.
8.7 It is strictly forbidden to post paper on the wall without permission during work, and it should be plasticized or packed in PE bags.
8.8 The report recorder leaves a certain distance from the processing table
Plastic product management
9.1 Control of plastic sheet and burr
a. Special staff in the tool and equipment disinfection room will inspect the plastic boxes and plastic baskets and trim the burrs, and select the damaged or cracked plastic boxes for return processing
The specific procedure is: visually inspect for burrs → repair (put the burrs in a special appliance) → rinse with water → exit the workshop
b. Handle plastic utensils with care. It is strictly forbidden to drag or bump back and forth on the table or other places. The plastic baskets of the product are strictly prohibited from beating or padding on the table to prevent man-made broken plastic. Appliances gradually appear aging after long-term use, so the processing workshop should check regularly and remove the aged plastic appliances in time.
c. New plastic utensils: All inspections are performed outside the production workshop, and a special person is organized to use a soldering iron to remove the burrs, burrs and easy-off parts of the dishes.
d. Try not to use plastic rulers, hard plastic clips, etc. in the workshop. Where stainless steel appliances can be used, consider replacing plastic appliances with corresponding stainless steel appliances.
e. The report clip used in the workshop should be far away from the production area. It is strictly forbidden to put it close to the product when filling in the report to prevent the product from being damaged or falling off.
f. The lamp protection cover shall be inspected every shift. If there is any damage, the lamp cover shall be replaced after the shift. If the lamp cover is damaged due to an emergency during the shift, it shall be dealt with as a major abnormal problem.
9.2 Control of plastic paper
a. The plastic paper used in the workshop is managed uniformly, and the burrs are completely removed during cutting to ensure that there is no damage to the plastic paper.
b. The color of the plastic paper is separated from the color of the product.
9.3 Control of plastic brush
a. The plastic brush used for cleaning tools and utensils must be dark and cannot be placed together with the brush for brushing the floor. The brush should be placed in a special basket or box when not in use.
b. All the sanitary utensils in the workshop are placed in the "sanitary ware storage room" when they are not in use, and the plastic brushes for cleaning tools and utensils are placed in a special basket or box and placed off the ground in the "sanitary ware storage room". Other sanitary appliances should also be neatly placed in the "sanitary appliance storage room". And neatly placed.
Bamboo and wood products management
10.1 Tools and equipment: It is strictly prohibited to use bamboo and wood materials such as wooden knife handles.
10.2 Sanitary utensils: The utensils used for cleaning and sanitation cannot be made of wood, such as wooden mops.
Hair control management
11.1 Processing staff
a. Before entering the workshop
·The processing personnel are outside the workshop and thoroughly clean up the hair and other foreign objects.
·Before wearing work clothes, first check the plain clothes and work clothes for hair inside and outside.
·After putting on the work clothes, check the hair in pairs, and then enter the next control process.
b. Workshop entrance inspection
At the entrance of the workshop, someone can only enter the workshop after checking the hair. After entering the processing workshop, it will be inspected and monitored by a dedicated person.
c. Workshop inspection
·A special person is set up during work to ensure that the inspection is carried out every hour. During the inspection, the staff is more than 30cm away from the table to prevent hair from falling into the product and not allowed to chat with the inspector.
·The hairs to be inspected should be placed together and processed uniformly.
·It is forbidden to pull sleeves during work to prevent hair from flowing out.
d. After class
·Make sure to take a bath and wash your hair twice a week.
· Guarantee regular work clothes every week.
·The staff who have haircuts must wash their hair when entering the workshop, and they must be carefully checked by the locker room personnel to ensure that there is no stubble before entering.
Latex gloves use management
The specific procedures are as follows:
a. Before the work enters the workshop, a special person is arranged at the entrance of the workshop to check whether the gloves are damaged.
b. The staff conduct regular self-inspection and replace the damaged immediately.
c. Check by a special person in the class (every time you wash your hands and disinfect them), replace them immediately if they are damaged, and make relevant records.
d. When workers leave the workshop after shift, a special person is set up at the entrance of the workshop to check whether the gloves are damaged.
e. If the gloves in the class are damaged (no defect), they should be replaced in time at the unified management office of the workshop gloves, and a special person will be assigned to supervise and inspect.
12.2 If the rubber of the glove is missing, re-check the product within the time period from the last inspection to the time of discovery, and find the rubber. If the rubber cannot be found, the product is judged as a non-conforming product.
13.1 Packing materials into the factory
a. Transportation: The vehicle must be clean, free of foreign matter, pollution, and kept dry.
b. Manufacturer: It must be a qualified supplier with manufacturer certificate, sanitary certificate, registration certificate, factory inspection certificate, etc.
·When receiving packaging materials, inspect their strength, layout, contamination, and foreign matter, etc., and enter the warehouse if they are qualified, and return if they are unqualified.
·For each batch of inner packaging bags, the laboratory personnel will conduct microbiological smear testing, and use them as qualified; return the unqualified products.
13.2 Use of packaging materials
·Confirm in advance the packaging materials, layout, and location of the imprint, etc., and use them only after they are qualified.
·Before packaging, check whether the product name specification is consistent with the product name specification on the packaging material.
b. When the product is replaced
·Product cleaning: the last product is thoroughly cleaned and all put into inventory.
·Physical cleaning: The materials used in the previous product are thoroughly cleaned, and all materials are clearly marked in the material warehouse to prevent mixing of different materials.
Packaging materials management
14.1 Personnel Management
a. Wear the work clothes neatly, and it is strictly forbidden to expose hair, hair and paper scraps.
b. Separate the inner and outer packaging personnel (in special circumstances, when the outer packaging operation is changed to the inner packaging operation, the paper scraps on the body must be thoroughly cleaned, and the hands must be disinfected).
c. Outsiders in the shift are strictly prohibited from entering the material room.
14.2 Indoor hygiene
a. Keep the ground, doors and windows, walls, rubber curtains, iron frames, and cases clean and free from damage, debris, and dirt.
b. Clean up the desk before and after the shift to keep it clean and free of debris.
c. The materials are placed neatly and orderly.
d. The humidity and moldy caused by rain in summer should be dried in time to control the reproduction and pollution of microorganisms and ensure that the strength of the carton is not affected, so as to prevent the damage of the carton from being mixed into the product.
14.3 Material Management
a. The inner and outer packaging materials are placed separately according to customers, product specifications, etc., and can be marked if necessary.
b. The materials should be padded with pads, placed off the ground or wall, and it is strictly forbidden to put them on the ground directly.
c. Cover all materials to prevent dust pollution.
14.4 Management of non-productive goods
a. It is strictly prohibited to store chemicals, bamboo and wood products, glass products, etc. in the material room.
b. It is strictly forbidden to store damaged or cracked equipment and articles in the material room.
Pest control management
15.1 Workshop control
a. The rubber curtains at the entrance and exit of the workshop, the delivery port, and the finished product storage should be kept clean and complete at all times.
b. The buffer room at the entrance of the raw material warehouse and material room should be kept hygienic and clean at all times.
c. The personnel entering and exiting the workshop close the door at will.
d. There should be no sanitary corners between the partitions between the workshop equipment and the wall, and no rotten rags or plastics or broken gloves should be placed randomly.
e. The stainless steel protective cover of the drainage outlet of the workshop and the door of the garbage outlet should not be opened for too long to prevent insects and rats from entering the workshop.
f. The filter screens of all intake and exhaust ports in the processing workshop must reach a certain density to prevent flying insects from entering the workshop and clean them regularly.
15.2 Fly hunting
a. Turn on the fly-killing lamp every day to catch and kill pests, and clean them regularly.
b. Manual hunting can be carried out in the class, and the dead bodies of flying insects can be found and processed separately.
c If necessary, apply pesticides after shifts or non-production hours, and then thoroughly clean them to prevent residues.