Bloom’s Taxonomy: LV, LVI
Definition
- LI. Remembering: Exhibit memory of previously learned material by recalling facts, terms, basic concepts and answers.
- LII. Understanding: Demonstrate understanding of facts and ideas by organizing, comparing, translating, interpreting, giving descriptions and stating main ideas.
- LIII. Applying: Solve problems in new situations by applying acquired knowledge, facts, techniques and rules in a different way.
- LIV. Analyzing: Examine and break information into parts by identifying motives or causes. Make inferences and find evidence to support generalizations.
- LV. Evaluating: Present and defend opinions by making judgments about information, validity of ideas, or quality of work based on a set of criteria.
- LVI. Creating: Compile information together in a different way by combining elements in a new pattern or proposing alternative solutions.
Topic Description
Hazard Analysis and Critical Control Point (HACCP) system is a science-based system which identifies specific hazards and measures for their control to ensure the safety of food. HACCP is a tool to assess hazards and establish control systems that focus on prevention rather than relying mainly on end-product testing and inspection. This topic provides the participants with the knowledge of the development of the HACCP plan or equivalent preventive control programs which follow the same or similar methodology. It provides the competencies needed to define the food safety policy, design, and maintain HACCP plans, develop training programs, create verification procedures including planning for internal and external audits and ensure continual improvement of HACCP plans and food safety programs. Finally, this topic covers the tools needed to build up the staff’s Emotional Intelligence (EI) and help them manage their stress during critical situations such as audits and recalls.
Learning Objectives
LO1. Evaluate the various Hazard Analysis Critical Control Point (HACCP) based programs for best relevance to the business mandate.
HACCP in itself is a system codified by CODEX Alimentarius; however, it has been interpreted by governments and private certification organizations and converted into a variety of codified programs under organizations such as the Global Food Safety Initiative (GFSI). Selecting the right HACCP based food safety management program requires a variety of business evaluations.
Detailed Competencies = Performance indicators include but are not limited to:
- P1. Evaluate the regulatory requirements for HACCP or Preventive Control within the commodity being produced.
- P2. Identify export or import activities that may impact on the type of HACCP program implemented and certified.
- P3. Evaluate the current and projected production volume and sales to identify scope and scale of mandatory HACCP requirements.
- P4. Analyse the certification and audit requirements from businesses in the supply chain such as retail customers.
- P5. Justify when internal capabilities are sufficient for design and maintenance of a HACCP plan, versus when it may be necessary to use external contractors.
LO2. Define the food safety policy, and provide the resources needed to the implementation of Prerequisite Plans (PRPs) and HACCP Plan
Managers should have the competencies to inspire trust in the company’s food safety policy, and lead by example. They should provide the required resources to implement the Prerequisite programs (PRPs) and HACCP plans.
Detailed Competencies = Performance indicators include but are not limited to:
- P1. Create an organizational commitment to food safety management practice within senior management.
- P2. Define and foster food safety culture practices across the entire organization.
- P3. Provide financial, management, and human resources needed to implement Prerequisite Plans and HACCP plans.
- P4. Motivate, instruct, and supervise staff to ensure the plans are implemented and standards are achieved.
- P5. Coordinate the organizational change management process related to implementation of a HACCP plan.
LO3. Design and develop HACCP plans.
Managers should have the competencies and knowledge to design HACCP plans. All food safety management systems are based on the Codex guidelines for the application of the HACCP system, with only coding differences across the various programs. Preventive Control Plans and other Food Safety Management systems follow similar logic and guidelines. Managers who are skilled with the Codex principles are able to design food safety programs based on other standards.
Detailed Competencies = Performance indicators include but are not limited to:
- P1. Implement the 12 HACCP steps that includes the 7 principles.
- P2. Assemble the HACCP Team.
- a. Identify the appropriate composition and knowledge required of an HACCP team.
- b. Create a cross functional background team (coming from different departments).
- c. Define competence requirements.
- d. Define roles and responsibilities of each HACCP team member.
- e. Define the scope of the HACCP plan – limit the study to a specific class of similar products and processes.
- f. Define the part of the food supply chain to be studied.
- P3. Describe the products.
- a. Describe the product, provide details of its composition, physical/chemical structure.
- b. Identify product ingredients and packaging materials.
- c. Describe labelling and safety information, processing treatments, storage requirements, shelf-life.
- d. Describe method of storage and distribution.
- P4. Identify the intended use.
- a. Specify where the product will be sold, as well as the target group especially if it happens to be a sensitive portion of the population (i.e., elderly, immunosuppressed, pregnant woman, and infants.
- P5. Construct a flow diagram.
- a. Illustrate an accurate and complete flow diagram and plant schematic in understand the specific processing operation.
- b. Identify potential hazards associated with the flow of raw materials from the point at which they enter the plant, through processing to departure.
- P6. On-site confirmation of flow diagram.
- a. Confirm the accuracy and completeness of the flow diagram.
- P7. Principle 1: Conduct a hazard analysis and consider control measures.
- a. Identify all potential hazards in a process and define the appropriate control measures.
- b. Identify all raw materials, ingredients, and packaging materials potential hazards.
- c. Apply regulations requirements, scientific research, hazard identification databases and review papers in conducting hazard analysis and risk assessment.
- d. Identify Likelihood and severity for each raw material, ingredients, packaging materials, and processing steps to determine risk which would be the base of the CCP if it is significant hazard based on risk (Use Matrix).
- e. Study the company complaints which assist in hazard identification.
- f. Interview employees to identify typical deviations within the process.
- g. Determine the level of control that should be implemented to control of hazard identified.
- P8. Principle 2: Determine Critical Control Points (CCPs).
- a. Use the Codex decision tree to determine the CCPs.
- b. Identify if a prerequisite program can manage and prevent the hazards
- c. Determine if the hazard would exist at a level that could cause harm
- d. Identify if a processing step at some point in the process will control the hazard.
- P9. Principle 3: Establish Critical Limits (CL) for each CCP.
- a. Determine CL based on scientific and research data, regulatory requirements and guidelines, experts, and experimental studies, etc.
- b. Conduct literature review to identify the critical limit.
- c. Create validation procedure to validate the critical limit and ensure its efficiency.
- d. Define how to measure the critical limit.
- P10. Principle 4: Establish a monitoring system for each CCP.
- a. Create a monitoring procedure that includes who, what, when, how, etc.
- b. Measure the performance level of each CCP with appropriate upper and lower limits.
- c. Determine when the performance level results in a loss of control at the CCP.
- d. Establish records that reflect the performance level of the system’s operation at the CCP to comply with the HACCP plan.
- P11. Principle 5: Establish Corrective Actions (CAs).
- a. Create measures to correct problems and return the product or process to a safe situation if a deviation occurs.
- b. Create immediate corrective action (who, what, when, how).
- c. Create preventive action that prevents the reoccurrence of the problem.
- P12. Principle 6: Establish verification procedures.
- a. Define and differentiate between validation and verification procedures.
- b. Establish procedures for verifying control at each of the CCPs.
- c. Establish procedure to validate the adequacy of the overall HACCP plans.
- P13. Principle 7: Establish documentation and record keeping.
- a. Provide examples of docs and forms used in the HACCP plans.
LO4. Review and maintain HACCP plans.
Managers should have the competences to periodically evaluate, with the minimum of once per year, the effectiveness of the HACCP system and provide measures to improve its effectiveness. Frequent evaluation and revision of HACCP system enhances the viability of a HACCP plan.
Detailed Competencies = Performance indicators include but are not limited to:
- P1. Review the HACCP plan. Review is prompted when:
- a. A new product line is designed.
- b. A process is amended when raw material or supplier change.
- c. A product is amended when there is a formulation change.
- d. There is a major change of equipment, storage condition, product use changes, packaging or distribution changes, cleaning procedures changes.
- e. There is a change in scientific knowledge of hazards and control measures.
- f. There is a new emerging hazard because of crisis or food fraud cases.
- g. Routine monitoring, audit outcomes or customers’ complaints illustrates system failure.
- h. There is a change in regulations or new regulatory requirements.
- P2. Review and revise the Prerequisite Program documentation.
- P3. Document changes to the HACCP plan and prerequisite programs in a change log.
- P4. Maintain an updated HACCP plan.
LO5. Develop an internal capacity building strategy for implementation of HACCP plans.
Managers should have the competences to provide training and ensure the competences of staff whose activities impact the food safety and the implementation of HACCP plans.
Detailed Competencies = Performance indicators include but are not limited to:
- P1. Identify the necessary competencies for personnel whose activities have an impact on food safety and HACCP implementation.
- P2. Identify reference and training materials on the application of HACCP to support the training program.
- P3. Create a training program or identify third party training opportunities to ensure personnel have the necessary competencies.
- P4. Ensure that personnel responsible for monitoring, verification and corrective actions of the HACCP plans have additional competencies in food safety risk assessment.
- P5. Evaluate the implementation and the effectiveness of the training program implemented or other actions taken.
- P6. Maintain records of training and actions taken.
LO6. Ensure continual improvement and effectiveness of the HACCP plan using External Audits, Internal Audits, and other verification activities.
Through audits and verification activities, mangers should ensure that the facility continually improves the effectiveness of the food safety program including HACCP plan or other equivalent programs.
Detailed Competencies = Performance indicators include but are not limited to:
- P1. Design and develop internal audit procedure, including criteria, scope, and frequency based on risks with a minimum of once per year.
- P2. Select and train the internal auditors.
- P3. Plan and organize external auditing.
- P4. Manage the non-compliance findings.
- P5. Make the necessary changes and updates to the HACCP manual to address the findings.
- P6. Communicate findings and changes with the rest of the staff to ensure the changes are implemented.
LO7. Build up Emotional Intelligence of the staff to handle stress and work effectively in implementing food safety programs including HACCP.
Manager should have the competences to build up Emotional Intelligence (EI) of the staff and embrace the implementation of food safety culture.
Detailed Competencies = Performance indicators include but are not limited to:
- P1. Be a role model and encourage integrity, problem solving and collaboration to achieve food safety objectives.
- P2. Identify the emotional stress under specific condition such as recall procedure or audit.
- P3. Regulate, handle the emotions and stress, and react proactively to the situation.
- P4. Identify others ’colleagues’ emotions and their state of mind in handling a critical situation.
- P5. Help manage others’ stress and prevent a breakdown resulting from facing a stressful situation.
- P6. Provide means to motivate the staff and have the capacity to self-motivate.
- P7. Practice the use of the EI elements through internal audit procedure and mock recall procedures.
- P8. Provide EI and soft skills training.
- P9. Provide feedback to staff and help them to embrace self-esteem and confidence.
Links to existing courses
Approved Accredited Training Programs (Academic, Industries, Private Trainer)
NA
Recognition of worker skills = Certification
NA
Evaluation technics / assessment
- Quizzes
- Written tests
- Multiple choice questions
