How Can I Streamline a Large Hazard Analysis for Practical Use?
Hi,
Working on updating a hazard analysis after extensive hazard identification process and for a while I have been banging my head against the wall on this issue for a while.
To give you some background. I am in the process of updating the haccp system to comply with stricter requirements in regard to how specific and accurate our hazard analysis should be. This is great, and I really think the hazard analysis is a very accurate representation of the process. The problem is that the sheer amount of data (number of rows) render the analysis itself practically useless and very demanding to keep up to date.
The reason it ends up being so bloated is that a specific hazard on a specific process step can have several causes. The likelyhood of it occuring can be very different and so on. At least 80 % of the hazards listed for each step are general for the whole process, like unsatisfactory cleaning, unclean hands, clothing, equipment and so on, but repeated for each relevant step.
Process step
Type
Causes
Corrective action
Probability (x x y x z)
Result desicion three
1
B
Contamination
Salmonella
Cleaning not satisfactory
Report to cleaning personelle and clean area before production start
GHP
Contamination
Salmonella
Personal equipment not sterilized due to operator not following routine
Compliance with routine is checked throughout the day, breaches of routine are corrected immediately.
GHP
Contamination
Salmonella
Personal equipment not sterilized due to unsatisfactory temperature in autoclave
Sensors inside the machine measures temperature, if minimum temperature is not reached an error message. Contact technical department immediately. Use other autoclave.
Contamination
Salmonella
Contamination via contact surface (pole) due to contaminated product being processed
Desinfect pole before each break, equipment is available on the position.
Contamination
Salmonella
Contamination due to perforation of digestive canal
Item is tagged for correction at later processing step, where visual contamination is hygienically removed if possible. Degree of contamination determines further handling, f. ex extensive contaminated items are discarded
OPRP
Contamination
Salmonella
Contamination via disposable clothing
Disposable protective clothing should be changed each time personell is entering the production area via hygiene lock. Disposable protective clothing must also be changed after contact with contaminated matter.
GHP
Contamination
Salmonella
Airborne contamination via steam from autoclave nearby
Not relevant
I personally hate that kind of analysis chart IMHO the risk matrix should be a separate doc from the analysis that alone will stream line the whole process
I gather you're in slaughter from some items, and ya, that is going to be a large program no matter what you do
HOWEVER, why mention the autoclave at all if it is physically so far away you've entered an N/A????
I use this format---then do a risk assessment by step as an addendum
Form 8: CCP determination and other control measuresHi Brumle,
:welcome:
Welcome to the IFSQN forums
I use an Excel file I call the HACCP Calculator for this purpose, it enables your whole hazard analysis to be summarized in one file:
HACCP Calculator.png 415.48KB 1 downloads
It includes assessment of likelihood and severity to decide how significant a hazard is and a decision tree to confirm CCPs.
Kind regards,
Tony