HACCP Verification Task Associating NRs Workshop: Open Beef 9-08-2012

HACCP Verification Task - Associating NRs Workshop: Open Beef

General Instructions
Work through this workshop with a partner. Read the workshop scenario and the reference material and answer the two workshop questions.

Inspection Methods
You are a GS-8 assigned to Open Beef INC. Open Beef is a beef slaughter and processing combination establishment that operates one shift from 6 a.m. to 2.30 p.m. The establishment has one HACCP plan covering its slaughter and further processing operations. You have a Slaughter HACCP verification task on your calendar for today. You decide to use the review and observation component to verify the monitoring, verification, and recordkeeping requirements at each CCP. You learned in the Inspection Methods course, that before you perform a task you need to review the establishments HACCP plan to familiarize yourself with the monitoring procedures and frequencies, critical limits, verification procedures and frequencies, etc.

Review the HACCP System Information

You proceed to the HACCP Coordinators office and request the HACCP plan which is provided below. At 10:35 a.m., you proceed to the kill floor and observed the monitor perform the lactic acid concentration measurement and record his result on the lactic acid monitoring record at the final wash CCP 5B. You review the results he has entered on the lactic acid record since the beginning of the shift.

Workshop Questions
After reviewing Open Beefs HACCP plan and the lactic acid monitoring record on pages 3 through 9 answer the following questions. 1. Has a noncompliance occurred based on reviewing the lactic acid monitoring record? If so, what type of noncompliance? What is the regulation that applies to this situation?

2. Is there a food safety concern as a result of this situation? Why?

Inspection Methods

HACCP Verification Task Associating NRs Workshop: Open Beef 9-08-2012

Gathering More Information

You asked the monitor, Mr. Smith, about the missing lactic acid measurement. He says that he was unable to perform the measurement because the other QA tech did not come in today and he was performing all of the sanitary dressing prerequisite program checks and the other CCP monitoring. You then notified the HACCP Coordinator, Melvin Sharp, of the failure to conduct the lactic acid concentration check at the frequency listed in the HACCP plan. Mr. Sharp says that he will identify additional employees and train them so they can conduct monitoring activities when needed. You observed Mr. Sharps measures to ensure that product produced at the time of the missed monitoring check was safe. As you prepare to document of the noncompliance in PHIS, you recall that you had nearly the same results last week, you reviewed the previous NR and the further planned action that was provided by establishment management was Mr. Smith, the monitor assigned to this station, was counseled on the importance of performing the monitoring checks at the frequency listed in the HACCP plan. You decide that these two noncompliances have the same cause, and that the further planned actions taken last week have not been effective in preventing the noncompliance from recurring.

Inspection Methods

HACCP Verification Task Associating NRs Workshop: Open Beef 9-08-2012

Establishment Name: Open Beef Slaughter and Raw Intact/Raw Non-intact Product HACCP Plan (Beef carcasses, primals and subprimals, trimmings, edible offal and AMR product)
CCP Number 1B Head Processing/ Boning Critical Limit Product will meet the acceptable Food Safety Standard (No visible feces, ingesta ,or milk) Monitoring Procedures QA personnel will monitor the zero tolerance / FSS CCP by visually inspecting 60 lbs of cheek meat, head meat and weasand meat (at the time of packaging) are free from visible fecal ingesta or milk at the QA inspection area once per production period (every 2 hours) and document the result on the Zero tolerance /FSS Monitoring Log Heads HACCP Records Zero tolerance/FS S Monitoring / verification Log - Heads Corrective Action Log Verification Procedures Documentation verification is completed once per shift and recorded on the Zero tolerance/FSS Monitoring Log - Heads . Direct observation of the monitoring activities is completed once per production week and recorded on the Zero tolerance/FSS Monitoring Log - Heads Corrective Actions Per 417.3 QA personnel are responsible for assuring that corrective actions are taken.

Inspection Methods

HACCP Verification Task Associating NRs Workshop: Open Beef 9-08-2012

CCP Number 2B Head Processing/ Boning

Critical Limit Surface of heads and tongues must be rinsed or sprayed with a solution that is 2% lactic acid with 10 psi.

Monitoring Procedures Once per production period (every 2 hours) QA personnel will measure the lactic acid concentration by using an organic acid test kit and document the result on CCP 2B Head Processing Monitoring Log Also once per production period (every 2 hours) QA personnel will visually monitor the lactic acid pressure gauge and document the result of the reading on CCP 2B Head Processing Monitoring Log

HACCP Records Head Spray Monitoring Log Corrective Action Log

Verification Procedures Documentation verification is completed once per shift and recorded on CCP 2B Head Processing Monitoring Log Direct observation of the monitoring activities is completed once per production week, and recorded on CCP 2B Head Processing Monitoring Log

Corrective Actions Per 417.3 QA personnel are responsible for assuring that corrective actions are taken

Inspection Methods

HACCP Verification Task Associating NRs Workshop: Open Beef 9-08-2012

CCP Number 3B Viscera Processing

Critical Limit Surface of visceral organs must be rinsed or sprayed with a solution of lactic acid 2% with 10 psi.

Monitoring Procedures Once per production period (every 2 hours) QA personnel will measure the lactic acid concentration by using an organic acid test kit and document the result on the Viscera Spray Monitoring Log Also once per production period (every 2 hours) QA personnel will visually monitor the lactic acid pressure gauge and document the result of the reading on the Viscera Spray Monitoring Log

HACCP Records Viscera Spray Monitoring Log Corrective Action Log

Verification Procedures Documentation verification is completed once per shift and recorded on the monitoring document. Direct observation of the monitoring activities is completed once per production week.

Corrective Actions Per 417.3 QA personnel are responsible for assuring that corrective actions are taken.

Inspection Methods

HACCP Verification Task Associating NRs Workshop: Open Beef 9-08-2012

CCP Number 4B Trim Rail

Critical Limit Carcass will meet the acceptable Food Safety Standard (No visible feces, ingesta, or milk)

Monitoring Procedures Once per production period (every 2 hours) before the wash cabinet QA personnel will visually inspect Three carcasses (6 sides) for Zero Tolerance requirements (No feces, ingesta, and/or milk) and document the result of the monitoring on the FSS Monitoring LogCarcasses

HACCP Records FSS Monitoring Log Carcasses Corrective Action Log

Verification Procedures Documentation verification is completed once per shift and recorded on the monitoring document. Direct observation of the monitoring activities is completed once per production week.

Corrective Actions Per 417.3 QA personnel are responsible for assuring that corrective actions are taken.

Inspection Methods

HACCP Verification Task Associating NRs Workshop: Open Beef 9-08-2012

CCP Number 5B Final Wash

Critical Limit Surface of carcasses must be rinsed or sprayed with a solution that is 2% lactic acid with 10 psi.

Monitoring Procedures Once per production period (every 2 hours) QA personnel will measure the lactic acid concentration by using an organic acid test kit and document the result on CCP 5B Carcass Spray Monitoring Log Also once per production period (every 2 hours) QA personnel will visually monitor the lactic acid pressure gauge and document the result of the reading on CCP 5-B Carcass Spray Monitoring Log

HACCP Verification Records Procedures Carcass Spray Documentation Monitoring Log verification is completed Corrective once per shift Action Log and recorded on the monitoring document. Direct observation of the monitoring activities is completed once per production week and recorded on the monitoring document

Corrective Actions Per 417.3 QA personnel are responsible for assuring that corrective actions are taken.

Inspection Methods

HACCP Verification Task Associating NRs Workshop: Open Beef 9-08-2012

CCP Number 6B Chilling

Critical Limit The surface temperature of carcasses, edible offal, and meat derived from heads will be 40F within 24 hours from the time on the scale ticket.

Monitoring Procedures Who: Refrigeration maintenance personnel What: the midline surface temperature of 10 carcasses, 10 pieces of edible offal and 10 pieces of meat derived from heads will be randomly selected and monitored When: within 24 hours from the time of the scale ticket. Where: In each hot box and offal cooler being used for current production. How: a calibrated thermometer will be used to measure the surface temperature

HACCP Verification Records Procedures Carcass Documentation Temperature verification is Monitoring Log completed once per shift Thermometer and recorded Calibration on the Log monitoring document. Corrective Action Log Direct observation of the monitoring activities is completed once per production week. Thermometer calibration verification is performed daily and the result is documented on the thermometer calibration Log.

Corrective Actions Per 417.3 QA personnel are responsible for assuring that corrective actions are taken.

Melvin Sharp Reassessed: Reassessed:

March 4, 2010

Revised--August 24, 2011

Melvin Sharp

February 10, 2011 Melvin Sharp February, 1, 2012 Melvin Sharp

Inspection Methods

HACCP Verification Task Associating NRs Workshop: Open Beef 9-08-2012

Open Beef: CCP 5B Carcass Wash Lactic Acid Monitoring Log Date: 2-2-2012 Time Lot Number Solution Concentration PSI Corrective Actions Monitored by Verified by /result

6:30 am 10:40 am

101 101

2.4 2.3

13 12

SS SS

Inspection Methods

HACCP Verification Task Associating NRs Workshop: Open Beef 9-08-2012

Document Inspection Results in PHIS

Working independently, log back into the PHIS computer and document the inspection results you identified in the workshop questions into PHIS. You will: Document the results of the Slaughter HACCP verification task Document the noncompliance on an NR Associate the NRs Use the following instructions as needed to get started in PHIS. If you need further instructions, consult the PHIS Quick Reference Guide. Logging in to PHIS 1. Log-in as: User Name: Password: FSIS_user FSIS

2. If needed, start Internet Explorer using the Icon on upper left of the desktop: Double click the Internet explorer ( PHIS comes up. Log In as: User name: Robert Allen Add the HACCP Verification Task to the Task Calendar Note: First, look at your task calendar for today. Do you have a routine Slaughter HACCP verification task scheduled? If not, follow these steps to add the task. 1. Left click on Task Calendar from the Navigation menu on the Home page, then left click the down arrow in the box next to select establishment and select Open Beef 2. Left click and hold on the slider bar to the right of the Establishment Task List panel, scroll through the list until you find a routine Slaughter HACCP verification task with the appropriate start and end dates 3. Find the Routine column for the task, and then left click on the Add link for the Slaughter HACCP verification task
Inspection Methods

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HACCP Verification Task Associating NRs Workshop: Open Beef 9-08-2012

4. In the pop-up box, Type Todays Date in the Start Date box or use the calendar icon to select todays date and left click on the Save button Initiate/Claim the HACCP Verification Task 1. Scroll down to the Task Calendar panel, left click the down arrow in the box next to Establishment that has the word all and select Open Beef 2. Find todays date and the Slaughter HACCP verification task that you just added 3. Right click on the Slaughter HACCP verification task on the calendar 4. Highlight and left click Document 5. Left click on the Activity tab, and left click the radio button in front of the word Review and Observation for the verification activity 6. Left click on the Regulations tab to determine the mandatory regulations that must be verified 7. Scroll down an left click on the save button 8. Left click on the close button Documenting the HACCP Verification Task Results 1. Scroll down to the Task Calendar panel, left click the down arrow in the box next to Establishment that has the word all and select Open Beef 2. Right click on the Slaughter HACCP verification task on the calendar 3. Highlight and left click Document 4. After the inspection results page opens, enter your inspection results Enter the mandatory regulations and any other regulations you verified, If noncompliance was found, document the noncompliance on an NR, associate the NR, and finalize the noncompliance

Inspection Methods

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