4. Corrective/ Preventive Action

Corrective action plans address the action to be taken when problems develop in a production process. Corrective action plans are essential components and important indicators of the strength of quality control programs. The primary emphasis of the plans should be on correction/prevention of problems in the production process. The type of plan used in a particular quality control program will be determined by the establishment and the processes conducted at the plant. Generally, corrective action plans should include the following features:

  • They should provide for the identification of problems or deviations in processes.
  • They should provide for the identification of the causes of problems.
  • They should specify the corrective steps to be initiated and the criteria for determining how non-compliant products should be handled.
  • The plans should provide that corrective/preventive measures be implemented after a determination that no safety hazards exist.
  • The plans should provide for documentation of the corrective and preventive measures taken.

Models

The following models are intended to be used as general guidelines to developers of quality control programs. They are not intended to be complete QC programs or a complete listing of all rotation al QC programs but offer a framework and one approach to QC program development. In actual QC programs, details regarding tests, action criteria, corrective actions, and responsible personnel would reflect the specific process and establishment circumstances. Any specifications or limits cited are only examples and do not establish or imply Agency standards.

 

Model 1—Preparation of a PQC Program for the Addition of 10-Percent Solution to Poultry

Raw Material Control
  • Poultry—Chicken breasts will be received frozen, examined for condition and immediately placed in the receiving dock freezer. (Specifications to be set by establishment.)
  • Dry ingredients—Up on receipt, the dry ingredients will be visually inspected for acceptance and immediately placed in the dry storage warehouse. (Specifications to be set by establishment.)
  • Corrective action —If either the poultry or the dry ingredients is found to be unacceptable, it will be tagged immediately and Quality Control will be notified. QC will evaluate and initiate appropriate product disposition.
  • Documentation —All critical checks and corrective actions will be recorded on the receiving log.
Process Control
  • Formulation control.
      • Formulation control—A pumping solution will be formulated according to the label formulation. One ingredient of the solution will be weighed by a quality control technician for each batch. If an ingredient is found to be more than 0.5 percent above or below the weight stated on the formula, the following will result: (1) the problem will be evaluated and the appropriate corrective action taken; (2) each ingredient of every batch will be checked until five consecutive batches are found to be in compliance.
      • Documentation —All formulation check results and corrective actions, if needed, will be recorded on the formulation log.
      • Scale accuracy control.
          • Scale checks—All scales associated with the pumping operation will be verified for accuracy before operations begin. Scale accuracy will be checked against a known weight. If a scale is found to be inaccurate, it will not be used until it has been calibrated.
          • Documentation —All scale check results and corrective actions, if required, will be recorded on the scale maintenance record.
Lotting
  • A lot will be defined as one shift’s production; a sub lot as approximately 500 pounds of product.
Added Solutions
  • Green weight determination —Each sublot will be identified with a unique code representing date and time of day the sublot is being produced.
    • The sublot will be weighed before pumping.
    • The identifying code and weight will be written on a tag, which will be attached to the combo bin containing the sublot.
  • Pumping—Every 30 minutes, 10 turkey breasts will be selected from a sublot before it is pumped. The 10 turkey breasts will be weighed, then passed through the pumping machine. The turkey breasts will be allowed to drain for 5 minutes, then weighed again.
    • Tolerances—Each pump check will not be more than 0.5 percent over the target pump of 10 percent. If a pump check is found to exceed the tolerance, all product back the last pump check will be retained and allowed to drain until it reaches the target pump. In addition, the pumping operations will be stopped, evaluated by a QC technician, and not allowed to start until the problem has been corrected.
    • Documentation —All pump checks and corrective actions, if needed , will be documented in the pumping log book.
  • Finished weight determination — After a sublot has been pumped, a final weight will be obtained and recorded on the pumping tag.
    • Tolerances—No sublot will be more than 1.2 percent above the target pump of 10 percent. The average of all sublots will meet the target pump. If any sublot or the average of the sublots exceeds tolerances, all product will be retained and allowed to drain until the target pump has been reached.
    • Documentation —All green weights, finished product weights, and corrective actions, if needed, will be recorded in the finished product log book.Note: Model also can be used in developing the following PQC programs:Percent Labeling Control

      Water-misted/ Ice-glazed Meat and Poultry Products

      Addition of Solution to Raw/ Cooked

      Meat and Poultry Products (Injection, Massaging, Tumbling, Basting, Marination, and Tenderization)

      Fat and/ or added water for Raw Product

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