Corrective Action - Freezer Storage Problems
We received a minor on our audit because "the freezer area has a significant amount of the aisle space blocked with pallets of frozen ingredients or finished product which impedes inspection."
My question to all of you: What could be appropriate corrective actions? We are currently in talks and getting quotes on an addition to the building including freezer and warehouse space, but that will not be complete until late fall - next spring.
Sometimes corrective actions take time and capital to accomplish. Auditing bodies know this. I would put that as your corrective action. "Facility intends to build an addition to the freezer to accommodate proper storage of ingredients and finished product." (or whatever).
Is there a freezer warehouse where you can rent space? We had to do that for a while with refrigerated storage for the yogurt plant I worked at under SQF.
Sometimes corrective actions take time and capital to accomplish. Auditing bodies know this. I would put that as your corrective action. "Facility intends to build an addition to the freezer to accommodate proper storage of ingredients and finished product." (or whatever).
Is there a freezer warehouse where you can rent space? We had to do that for a while with refrigerated storage for the yogurt plant I worked at under SQF.
If you do rent space, check licensing. In some states you have to a separate type of license for the Health District.
Dear Pizza&Sandwich,
I agree with previous suggestions, it's sometimes termed a "delaying action" if nothing can be done.
IMEX, it is also beneficial to submit some documental activity even if none immediately intended.
I experienced a NC that the insulation of one cold storage room (filled with over-produced goods) was inadequate which it was (snow-covered wall!). Impossible to transfer / empty room so I obtained some quotations to repair the wall. No further comment. I'm sure auditors must have seen it all before also. :smile:
Rgds / Charles.C
We currently have 300+ pallets at another location. Most of these are distributed to customers from that location, some are brought back to our facility.
Sometimes corrective actions take time and capital to accomplish. Auditing bodies know this. I would put that as your corrective action. "Facility intends to build an addition to the freezer to accommodate proper storage of ingredients and finished product." (or whatever).
I brought this point up several times to the auditor and he indicated that this may not be approved by the certification body (they approve before the auditor).
We currently have 300+ pallets at another location. Most of these are distributed to customers from that location, some are brought back to our facility.
I brought this point up several times to the auditor and he indicated that this may not be approved by the certification body (they approve before the auditor).
Well.. I don't know your auditor or CB and while there is usually a time frame for NC's to be accomplished in there are usually also a level of understanding when it comes to major projects.
Your situation is not one that is an immediate food safety concern. It can cause an issue with FIFO or inspection. Maybe, depending on the circumstances, you can institute a temporary order that pallets can only sit in one location for 24 hours on the floor before they have to be moved to allow for inspection of the area behind them... or something as a immediate temporary solution until the expansion can take place.
Hi Pizza&Sandwich,
The above suggestions are good for long term, and yes in some cases this will be accepted. I've done it plenty of times. I'm in the middle of one right now, having to build another toilet in the gentlemen's wash room. However, in this NC there can be some short resolutions before moving items to a different building or creating more space. This may also depend on what section the auditor got you for. Your corrective action could be something as simple as saying that your logistics would improve which would cause less product to be in the aisles to something as painting some lines on the floor to allow a pathway or restrictions for pallets not to placed.
Have you done the 5 why's for root cause?
Have you done the 5 why's for root cause?
Sure:
Why does the freezer have pallets stored in the aisle that impedes inspection?
Because there are too many pallets to be stored on the racks properly and the freezer is inadequate
Why is the freezer inadequate?
Because we produce anywhere from 40-75 pallets of product a day, have to store enough 'raw' materials for at least a week's worth of production, and store enough finished goods to be shipped out for a week
Why do we produce & store so much product?
Because we are a manufacturer, distributor, and re-distributor, and our customers expect to receive product when they order it
Why do we manufacture, distribute, and re-distribute?
Because that's what the company was founded on and how we make our money
Why?
Because the owners say so :biggrin:
hello, normal wise auditors expect evidences to close the NC of the CORRECTIONS, but not of the action plan of the corrective action.
So, if you send training records, change of procedures, signs in the floor to keep empty some areas, posts in the wall, etc., that would be enough for the auditor.
But of course also send the action plan for the corrective action that could demand long time actions, and investments.
I attach the BRC Root Cause Analysis, may be the Ishikawa treatment could lead you to several others plans beyond “Mom said so” (just kidding!!)
J
Leila
Sure:
Why does the freezer have pallets stored in the aisle that impedes inspection?
Because there are too many pallets to be stored on the racks properly and the freezer is inadequate
Why is the freezer inadequate?
Because we produce anywhere from 40-75 pallets of product a day, have to store enough 'raw' materials for at least a week's worth of production, and store enough finished goods to be shipped out for a week
I think this is where your 5 whys went off the rails -
Try "Why isn't there 6 inches between pallets on the floor"
Because we can fit in 60 pallets with 6 inches between them, but we can fit in 75 without rows between them
So I would suggest as a short term corrective action (until the new freezer arrives)
Using marking tape to put down areas where it is acceptable to place pallets
Making sure when there are the maximum amount of pallets the freezer is labelled as to capacity
Storing pallets above capacity at the secondary location
Freezer space is a bigger issue than just pest control inspection - you need to make sure nothing is leaking, and the more stuff is clumped together, the harder it is to cool the insides
Trust me, we have a huge space issue right now. We're expanding the building and we're about to get a walkin twice the size of our current situation. It's also a safety hazard for us not to have clear walkways. We had an elderly employee who was moving stuff between two pallets and tripped and hurt her knee pretty badly, so now the rules is if you go to put something away and it's in an asile or walkway, you're not allowed to do that.
Man, a guy like me can really learn a lot just from reading the random thread in this forum -- love this place!
Thanks for the question and detailed responses with thorough explanations.
Jeff