F9 SC AGILE ENG Participant Exercise Workbook

Participant Exercise Workbook
Global Standard
Food Safety Issue 9
Food Safety Issue 9

Sites Conversion
Agile Training (Virtual and Face to Face)
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1
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Sites Conversion Global Standard Food Safety (Issue 9)

F9-SC-AGILE-ENG- Participant exercise workbook Performance Enhancement -Training
Version: Agile format – September 2022 Page 2 of 25
Copyright © BRCGS 2022 protected under UK and international law.
Prework:
Your prework is to ensure you have read through and understood the
Prework: The Global Standard for this Issue
including
Prework: The Glossary for the Global Standard for this Issue
and reviewed the case study document provided:
Prework: Case study & activities.

Contents
Prework: The Global Standard for this Issue.......................................................................................................3
Prework: The Glossary for the Global Standard for this Issue...........................................................................3
Prework: Case study & activities..........................................................................................................................3
Exercise GSF9002 (Sites) - Food safety culture plan activities.................................................................................5
Exercise GSF9003 (Sites) - The food safety plan – HACCP.....................................................................................6
Exercise GSF9004 (Sites) - Internal audits..............................................................................................................12
Exercise GSF9005 (Sites) - Supplier and raw material approval and performance monitoring...............................13
Exercise GSF9006 - Management of Outsourced processing..................................................................................14
Exercise GSF9007 - Traceability test......................................................................................................................15
Exercise GSF9008 – Incident Management.............................................................................................................16
Exercise GSF9009 - Food defence..........................................................................................................................17
Exercise GSF9013 - Knowledge checks..................................................................................................................18
Exercise GSF9015 - Allergen control......................................................................................................................20
Exercise GSF9021 – Designation of product risk zones..........................................................................................21
Exercise GSF9023 – Traded products.....................................................................................................................22
Exercise GSF9024 – Knowledge Check – quick review.........................................................................................23

Exercise GSF9002 (Sites) - Food safety culture plan activities
The object of this exercise: to recognise compliance to requirements 1.1.2 of the Standard
Task:
Identify three (3) key areas that Sunny Salads could improve within their food safety and quality culture plan based on
the requirements of the Standard (1.1.2)
Answer:

Exercise GSF9003 (Sites) - The food safety plan – HACCP
The object of this exercise: To demonstrate understanding of the requirements of the Standard regarding the food
safety plan.
Task:
Review each of the requirements outlined in section 2 of the Standard - The food Safety plan. After each clause,
identify:
 What evidence is required,

 What needs to be documented (e.g. specific details), and
 What records should be maintained to demonstrate compliance.
Answer:
2.1 The HACCP food safety team (equivalent to Codex Alimentarius Step 1)
Evidence Documentation Records
2.2 Prerequisite programmes


2.3 Describe the product (equivalent to Codex Alimentarius Step 2)
2.4 Identify intended use (equivalent to Codex Alimentarius Step 3)

2.5 Construct a process flow diagram (equivalent to Codex Alimentarius Step 4)

2.6 Verify process flow diagram (equivalent to Codex Alimentarius Step 5)
2.7 List all potential hazards associated with each process step, conduct a hazard analysis and consider any
measures to control identified hazards (equivalent to Codex Alimentarius Step 6, Principle 1)
• •

2.8 Determine the CCPs (equivalent to Codex Alimentarius Step 7, Principle 2)
•
•
2.9 Establish validated critical limits for each CCP (equivalent to Codex Alimentarius Step 8, Principle 3)
• •
•
2.10 Establish a monitoring system for each CCP (equivalent to Codex Alimentarius Step 9, Principle 4)
• •

2.11 Establish a corrective action plan (equivalent to Codex Alimentarius Step 10, Principle 5)
• •
•
2.12 Validate the HACCP plan and establish verification procedures (equivalent to Codex Alimentarius Step 11,
Principle 6)
• •
•
2.13 HACCP documentation and record-keeping (equivalent to Codex Alimentarius Step 12, Principle 7)

•
• •

Exercise GSF9004 (Sites) - Internal audits
The object of this exercise is to demonstrate understanding the Standard requirements for internal audits
Task:
1. List the differences between the requirements for internal audits and the requirements for inspections.
2. Does the Internal Audit programme of the case study cover the requirements for internal audits?
Answer:

Exercise GSF9005 (Sites) - Supplier and raw material approval and
performance monitoring
The object of this exercise is to understand the Standard requirements for approval and performance monitoring of
suppliers.
Task:
If you were the QA manager of Sunny Salads, what steps would you undertake to verify the traceability system of:
 Zopack
 Freddie’s Food Brokers
 Quick Grow Farms
Answer:
Supplier Name Approval Method Traceability system verification

Zopack
Freddie’s Food Brokers
Quick Grow Farms

Exercise GSF9006 - Management of Outsourced processing
The object of this exercise is to demonstrate an understanding of requirement 3.5.4 – Management of outsourced
processing.
This is a scenario based activity.
Scenario:
Sunny Salads includes a dressing sachet with each of their salads. These dressings are manufactured and packed by an
external supplier (Yummy Dressings) using a proprietary recipe which is provided by Sunny Salads. The packaging is
branded with the logo and colours of Sunny Salads. Sunny Salads also dictates the raw materials to be used in their
dressings.
1. Based on the requirements of 3.5.4 would this scenario be classed as outsourced processing? Justify your answer.
Answer:
2. Does Sunny Salads outsource any processing? If yes, which process is outsourced?
Answer:

Exercise GSF9007 - Traceability test
The object of this exercise is to demonstrate an understanding of requirement - 3.9 Traceability

Task:
1. Which clause of the Standard mandates how often a traceability test must be performed? What is this frequency?
2. Using the nominated process steps from Sunny Salads, identify key records and the linking parameter(s) that
could be used to demonstrate traceability.
Answer:
Question 1:
Question 2:
Step No. Process Step Key records for traceability Linking parameter

Exercise GSF9008 – Incident Management
The object of this exercise is to encourage participants to think critically about incidents and emergency situations
that impact food safety, authenticity, legality or quality need to be effectively managed.
Task:
Read the following scenario to participants.
Scenario:
All laboratory staff have called in sick and are likely to be away for several days.
How could Sunny Salads manage this situation so the there is no impact on food safety, authenticity, legality or
quality ?
Answer:
Exercise GSF9009 - Food defence
The object of this exercise is to demonstrate an understanding of requirement – 4.2 Food Defence.
Task:
What evidence could a site provide to an auditor to demonstrate compliance to the requirements of 4.2 Food Defence?
Answer:

Exercise GSF9013 - Knowledge checks
The object of this exercise is to assess understanding for sections 1-4
Task
Select the correct answer for each question:
Which of the following is a fundamental section?
a. Pest Management (4.14)
b. Control of operations (6.1)
c. Production risk zones – high risk, high care and ambient high care (8)
d. Product control (5)
Answer:
The objective of senior management at the audit is …..

a. To have any senior manager present at the audit
b. To provide rationale of the non-conformance
c. To agree on the non-conformance as it happens and decide the corrective action
d. To direct the auditor to the relevant experienced staff to answer queries
Answer:
Maintaining suitable background information taken into account when preparing the HACCP or food safety plan is
compliance to which of the following clauses?
a. 2.3.2
b. 2.7.1
c. 2.13.1
d. 3.2.1
Answer:
Which is the best option to conduct an internal audit in compliance with the Standard?
a. An appropriately trained auditor responsible for the process
b. An external food safety consultant responsible for the site operation
c. An auditor highly recommended by a supplier
d. An appropriately trained auditor independent to the process
Answer:
From the requirements for ‘Building fabric, raw material-handling, preparation, processing, packing and storage
areas’, identify which clause requires that mezzanine floors located adjacent to production lines with open products
are designed to prevent contamination of products and production lines?
a. 4.4.2
b. 4.4.7
c. 4.4.6
d. 4.4.8
Answer:

Exercise GSF9015 - Allergen control
The object of this exercise is to demonstrate an understanding of requirement – 5.3 Management of Allergens.
Task:
Review the Allergen Risk Assessment, Product Description and Intended Use, Flow Process Diagram and Process
Narrative documents prepared by Sunny Salads. Based on the products produced and handled at the site, identify:
1. If the Allergen Risk Assessment is correct. Ensure that you justify your findings.
2. At least five (5) control measures that could be implemented to prevent potential allergen cross-contact.
Answer:

Exercise GSF9021 – Designation of product risk zones
The object of this exercise is to correctly define product risk zones and requirements within a facility.
Task:
This activity is divided into three (3) parts.
1. Using the definitions outlined in appendix 2, identify the likely production risk zone for the products produced by
Sunny Salads (before packing).
2. Refer to the site map document in the Sunny Salads case study. Sunny Salads has constructed a removable wall
between the salad production area and the salad wash / cut area. How could the site demonstrate conformance with the
requirements of 8.2.3?
3. Identify what type of clothing staff would need to wear when they are working in the salad production area.
Answer:
Exercise GSF9023 – Traded products
The object of this exercise is to understand the scope of a traded product
Task:
Select which example is a traded products?
a) A site buys sugar sacks for their product, but also sells the sugar sacks to competitors and sister companies.
b) A site buys sugar sacks and sells them to competitors and sister companies.
c) A site stores sugar sacks for a sister company that makes a sugar product
d) A site buys sugar sacks for their product, sends the product off site for packaging which returns to the
company to sell to its competitors.
Answer:

Exercise GSF9024 – Knowledge Check – quick review
The object of this exercise is to assess understanding for sections 5-9
Task
True or false? "Production of frozen vegetables" is acceptable scope wording.
a. FALSE
b. TRUE
Answer:
What is the MAIN purpose of the closing meeting?
a. Thank all the relevant personnel for their time and effort
b. Advise the outcome of the audit
c. Review the findings of the audit with the company
d. Verify and conduct further documentation checks
Answer:
What evidence should the auditor evaluate to determine conformity with record-keeping requirements, when
electronic records are stored on an internal server? (Choose the BEST answer)
a. Back-up process and security mechanisms
b. Training and qualifications of IT staff
c. Management review meeting report
d. Food safety and quality manual
Answer:

Which record(s) should be assessed to evaluate finished product compliance with the customer's specification?
(Choose the BEST answer)
a. Finished product inspection and test results
b. Customer approval for finished product specification
c. Current laboratory accreditation certificate
d. Critical control point (CCP) monitoring and verification records
Answer:
As part of the vertical audit, the auditor must check the product label against
a. The recipe only
b. The specification and shelf life
c. The origin, recipe and shelf life
d. The recipe, specification and shelf life
Answer:
Who decides which organisations can read the site's audit report?
a. The certification body
b. BRCGS
c. The audit report is available for everyone to read
d. The site
Answer:


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Participant Exercise Workbook

Food Safety Issue 9

Sites Conversion Global Standard Food Safety (Issue 9)

Sites Conversion Global Standard Food Safety (Issue 9)

Sites Conversion Global Standard Food Safety (Issue 9)

Sites Conversion Global Standard Food Safety (Issue 9)

 What evidence is required,

Evidence Documentation Records

2.2 Prerequisite programmes

Sites Conversion Global Standard Food Safety (Issue 9)

2.4 Identify intended use (equivalent to Codex Alimentarius Step 3)

2.5 Construct a process flow diagram (equivalent to Codex Alimentarius Step 4)

Evidence Documentation Records

Sites Conversion Global Standard Food Safety (Issue 9)

Sites Conversion Global Standard Food Safety (Issue 9)

Evidence Documentation Records

Sites Conversion Global Standard Food Safety (Issue 9)

Evidence Documentation Records

Sites Conversion Global Standard Food Safety (Issue 9)

Sites Conversion Global Standard Food Safety (Issue 9)

Sites Conversion Global Standard Food Safety (Issue 9)

Supplier Name Approval Method Traceability system verification

Freddie’s Food Brokers

Quick Grow Farms

Sites Conversion Global Standard Food Safety (Issue 9)

Sites Conversion Global Standard Food Safety (Issue 9)

The object of this exercise is to demonstrate an understanding of requirement - 3.9 Traceability

Sites Conversion Global Standard Food Safety (Issue 9)

Sites Conversion Global Standard Food Safety (Issue 9)

The objective of senior management at the audit is …..

Sites Conversion Global Standard Food Safety (Issue 9)

Sites Conversion Global Standard Food Safety (Issue 9)

Sites Conversion Global Standard Food Safety (Issue 9)

What is the MAIN purpose of the closing meeting?

b. Advise the outcome of the audit

c. Review the findings of the audit with the company

d. Verify and conduct further documentation checks

a. Back-up process and security mechanisms

b. Training and qualifications of IT staff

c. Management review meeting report

d. Food safety and quality manual

Sites Conversion Global Standard Food Safety (Issue 9)

a. Finished product inspection and test results

b. Customer approval for finished product specification

c. Current laboratory accreditation certificate

d. Critical control point (CCP) monitoring and verification records

a. The recipe only

b. The specification and shelf life

c. The origin, recipe and shelf life

d. The recipe, specification and shelf life

a. The certification body

c. The audit report is available for everyone to read

Sites Conversion Global Standard Food Safety (Issue 9)

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