Andy Chendra

CORPORATE QUALITY MANAGER

PT HEINZ ABC INDONESIA
 AGENDA

DEFINISI QUALITY

ELEMENT QUALITY DI INDUSTRI PANGAN

HISTORY OF QUALITY

QUALITY CONTROL VS QUALITY ASSURANCE

QUALITY ASSURANCE IN FOOD INDUSTRY

SUMMARY

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 QUALITY

APAKAH YANG DI MAKSUD DENGAN QUALITY ?

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 Quality

Keseluruhan karakteristik dan

kemampuan dari suatu produk dan
service yang mampu memuaskan
kebutuhan konsumen baik yang
eksplisit maupun implisit.
 QUALITY

QUALITY ADALAH “ QCDSSME ” (QUALITY,

COST, DELIVERY, SERVICE, SAFETY, MORALE &
ENVIRONMENT

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 QUALITY

• Q (quality) : berarti
mutu dari
produk/jasa yang
dihasilkan

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 QUALITY

• C (Cost) : berarti mutu

dari biaya
(tidak ada biaya non-
quality, biaya produksi
optimum – harga bisa
ditekan)

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 QUALITY

• D (Delivery) :
berarti mutu dari
penyampaian barang/jasa
(penyampaian yang tepat
waktu sesuai permintaan)

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 QUALITY

• S (Service) : berarti
mutu dari pelayanan
(misalnya pelayanan
kepada pelanggan
internal maupun
eksternal)

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 QUALITY

• S (Safety) :
berati mutu dari
keamanan (misalnya
pada saat barang/jasa
dipergunakan)

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 QUALITY

• M (Morale) : berarti mutu

dari semangat (misalnya
semangat/ adanya kemauan
untuk melayani pelanggan)

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 QUALITY

• E (Environment) : berarti mutu

dari dampak pencemaran
terhadap lingkungan hidup
(misalnya limbah/sampah yang
aman terhadap lingkungan)

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 HISTORY OF QUALITY SYSTEM

Quality system mana yang terbaik?

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 HISTORY OF QUALITY SYSTEM

Craftsmen model: association of

craftsmen – Guilds.
Setting the standard by 100%
inspection and early consumer
protection.

Industrialization: mass production, rapid volume

growth Inspection model, a full time inspection job
was created to make decision to reject or accept.
Quality Control Manager (separate from
manufacturing) was created after more and more
quality problems occured
HISTORY OF QUALITY SYSTEM

Walter Shewhart: introduce first modern control

chart and Statistical Quality Control, including
PDCA cycle.

W. Edwards Deming: placed great importance of

management role in quality (believing
management responsible for 94% quality
problems). Popularized PDCA (Deming cycle)
based on Shewhart’s work. His 14 points plan is a
complete philosophy of management
 HISTORY OF QUALITY SYSTEM

Joseph M Juran: Develop quality trilogy: Quality

planning, quality control and quality
improvement. Focus not only to end customer
but also external and internal customer.
(supplier process customer)

Armand V Feigenbaum: Originator of “Total

Quality”. He define as “an effective system for
integrating quality development, quality
maintenance and quality improvement efforts
of various groups within an organisation to
enable production and service at the most
economical levels that allow full customer
satisfaction.
 HISTORY OF QUALITY SYSTEM

Military Industry: Quality becoming

important safety issue. It was not possible to
do 100% inspection. Military standard
sampling scheme was introduce.

However, the system is not integrated in

the operation system in most industry.
Only last until the military contract
finished.
 HISTORY OF QUALITY SYSTEM

Japan case: Japan product at that time was known as Poor

Quality and cheap immitation Product. After war, they invite
Deming, Juran and Feigenbaum to give their inputs. Based on
their inputs Japan developed original “Total Quality”.
Japan’s strategies represented the new “total quality” approach.
Rather than relying purely on product inspection, Japanese
manufacturers focused on improving all organizational processes
through the people who used them. As a result, Japan was able
to produce higher-quality exports at lower prices, benefiting
consumers
By late 1960’s – early 1970’s, import Japan to USA and Europe
increase significantly, not because of the lower price but better
quality
HISTORY OF QUALITY SYSTEM

Kaoru Ishikawa: made many contributions to

quality, the most noteworthy being his total
quality viewpoint, company wide quality control,
his emphasis on the human side of quality, the
Ishikawa diagram and the assembly and use of
the “seven basic tools of quality”: Pareto; Cause
and effect diagrams; Stratification; Check sheets;
histogram; scatter charts and process control
charts.
HISTORY OF QUALITY SYSTEM

Genichi Teguchi: Robust product design and

insensitive to variation in the manufacturing process
is preferred, rather than attempt to control all the
many variations during actual manufacture. Focus
on Design quality (off-line quality): System design;
Parameter design and Tolerance design known as
“Teguchi Method”
HISTORY OF QUALITY SYSTEM

Shigeo Shingo: is strongly associated with Just-in-

Time manufacturing, and was the inventor of the
single minute exchange of die (SMED) system in
which set up times are reduced from hours to
minutes, and the Poka-Yoke (mistake proofing)
system.

He distinguished between “errors”, which are

inevitable, and “defects”, which result when an
error reaches a customer, and the aim of Poka-
Yoke is to stop errors becoming defects.
Zero quality control is the ideal production system
and this requires both Poka-Yoke and source
inspections.
 HISTORY OF QUALITY SYSTEM

Philip B. Crosby: is known for the concepts of “Quality is Free” and

“Zero Defects”, and his quality
improvement process is based on his four absolutes of quality:
• Quality is conformance to requirements
• The system of quality is prevention
• The performance standard is zero defect
• The measurement of quality is the price of non-conformance
Two of his fourteen steps to quality improvement are:
• Management is committed to a formalised quality policy
• Form a management level quality improvement team (QIT) with
responsibility for quality
 QC VS QA

Apa perbedaan antara Quality Control, Quality

Assurance dan Quality Mangement ?

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 QC VS QA
Quality Control System Vs Quality Assurance System

QUALITY QUALITY QUALITY

FUNCTION CONTROL ASSURANCE MANAGEMENT

CONTINUOUS
EMPHASIZE INSPECTION PREVENTION
IMPROVEMENT
MODE REACTIVE PROACTIVE PROSPECTIVE
FOCUS PRODUCT PROCESS BUSINESS
TIME SHORT MEDIUM LONG
QC,PRODUCTION &
RESPONSIBILITY QA CORPORATE
WAREHOUSE *

Doing Doing the Setting

Things Right the Right
Right Things Frame

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 QC VS QA

Quality Control:

RM/PM Processing Filling Packing Finished Goods Customer

Warehouse Production Production Warehouse

Release, Release, Release Release,

RM/PM WIP FG
To WH

QC QC QC

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 QC VS QA

Quality Assurance:

RM/PM Processing Filling Packing Finished Goods Customer

Warehouse Production Production Warehouse

Release, Release, Release Release,

RM/PM WIP FG
To WH

Warehouse-QA Production QA

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 QUALITY ELEMENT

Apakah yang di sebut makanan/minuman

berkualitas?

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 QUALITY ELEMENT

KEPUASAN KONSUMEN
KEAMANAN PANGAN (CONSUMER SATISFACTION)
(FOOD SAFETY)

PEMENUHAN PERATURAN
(COMPLIANCE)

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 QUALITY ASSURANCE

• Hubungan antara GMP, HACCP dan Quality

System. Manakah yang harus di
implementasikan terlebih dahulu?

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 QUALITY ASSURANCE
KEAMANAN PANGAN
(FOOD SAFETY)

Food Safety Management System

QUALITY
HACCP
GMP SYSTEM

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 QUALITY ASSURANCE
KEAMANAN PANGAN
(FOOD SAFETY)

GOOD MANUFACTURING PRACTICE

• Personnel hygiene • Integrated Pest Management

• Building and lay out • Vendor Management
• Environment and facility • Lot coding & Traceability
• Hygienic design of machine, equipment • Good Warehouse Practice
• Cleaning and Sanitation • Transport and Distribution
• Foreign Material Prevention • etc.
• Start up, Shut down – Change over

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 QUALITY ASSURANCE
KEAMANAN PANGAN
(FOOD SAFETY)

HAZARD ANALYSIS CRITICAL CONTROL POINT

Sistem jaminan mutu keamanan pangan yang

berdasarkan pada analisa dan pengetahuan
bahaya yang dapat timbul pada setiap titik atau
tahap produksi dan bagaimana pencegahannya
melalui pengendalian titik-titik kritis

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 QUALITY ASSURANCE
KEAMANAN PANGAN
(FOOD SAFETY)

HAZARD ANALYSIS CRITICAL CONTROL POINT

• 1959 : Pertama kali dikembangkan oleh Pillsbury Company
untuk makanan astronot
• 1971 : Pemaparan konsep HACCP pertama kali kepada
masyarakat di US dalam suatu Konferensi Nasional Keamanan
Pangan
• 1972 : Pillsbury Company memberikan Pelatihan HACCP ke FDA
• 1973 : Dokumen lengkap HACCP diterbitkan oleh Pillsbury
Company, kemudian diadopsi oleh industri makanan kaleng
berasam rendah
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 QUALITY ASSURANCE
KEAMANAN PANGAN
(FOOD SAFETY)

HAZARD ANALYSIS CRITICAL CONTROL POINT

• 1985 : NAS (National Academy of Sciences) merekomendasikan
HACCP karena lebih memberikan jaminan keamanan pangan
jika dibandingkan dengan sistem pengawasan produk akhir
• 1987 : NAS membentuk National Advisory Committee on
Microbiological Criteria for Foods (NACMCF) dan
memperkenalkan 7 Prinsip HACCP
• 1991 : Sistem HACCP mulai diperkenalkan oleh Codex
Alimentarius Commission (CAC)
• 1998 : Sistem HACCP diadopsi di Indonesia dan diterjemahkan
dalam Standar Nasional Indonesia
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 QUALITY ASSURANCE
KEAMANAN PANGAN
(FOOD SAFETY)

HAZARD ANALYSIS CRITICAL CONTROL POINT

• Sistematik dan scientific
• Proaktive dan pencegahan
• Fokus pada keamanan pangan
• Diakui Internasional
• Due diligence support
• Diimplementasikan di seluruh rantai makanan
• Keamanan pangan di mulai dari product development
stage
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 QUALITY ASSURANCE
HAZARD ANALYSIS CRITICAL CONTROL POINT
KEAMANAN PANGAN
(FOOD SAFETY)

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 QUALITY ASSURANCE

• Apakah sebelum ada HACCP, keamanan

pangan di industri pangan kurang baik?

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 QUALITY ASSURANCE
PEMENUHAN PERATURAN
(COMPLIANCE)

REGULATORY COMPLIANCE

MARKET/LOCAL REGULATION
• Halal
• Berat bersih
• Aturan Label
INTERNATIONAL STANDARDS
• Allergen
• Bahan tambahan pangan
• SNI
INTERNAL/COMPANY STANDARDS • Kontaminan, etc.

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 QUALITY ASSURANCE
KEPUASAN KONSUMEN
(CONSUMER SATISFACTION)

• Sensory Evaluation / organoleptik

• Kemasan/packaging : convenience, umur simpan
• Kandungan gizi / fungsional
• Service, delivery

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 QUALITY ASSURANCE

• Adakah bagian-bagian penting dalam business

process yang sangat menentukan kualitas
produk akhir?

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 BUSINESS PROCESS

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 QUALITY ASSURANCE

1. R &D – Pengembangan produk dan/atau kemasan baru

2. Supplier Quality Assurance

Bukan berarti bagian atau tahapan lain tidak berpengaruh terhadap Quality;
Semua tahapan process memiliki peran dalam menentukan quality product
akhir

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 QUALITY ASSURANCE

1. R &D – Pengembangan produk dan/atau kemasan baru

Quality haruslah direncanakan sejak awal produk

dikembangkan; contoh:
• Kesesuaian terhadap peraturan
• Pre-HACCP
• Bagaimana produk akan dikonsumsi
• Di mana produk akan di jual; distribusi
• Aturan Label
• Allergen
• Pemenuhan SNI, Halal
• Kontaminan, etc.
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 QUALITY ASSURANCE

1. R &D – Pengembangan produk dan/atau kemasan baru

Quality tidak terjadi begitu saja, melainkan melalui

perencanaan yang matang, di implementasi dengan baik
dan dilakukan oleh orang bukan mesin.

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 QUALITY ASSURANCE

2. Supplier Quality Assurance

Pemilihan supplier harus di dasarkan pada:

1. Business Commercial aspects
2. Technical and Quality Relates-aspects.

Garbage in = Garbage Out

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 QUALITY ASSURANCE

2. Supplier Quality Assurance

Pemilihan supplier harus di dasarkan pada:
1. Business Commercial aspects:
- Kondisi keuangan perusahaan
- Kemampuan supply yang berkelanjutan
- Siapakah supplier ini?
- Harga yang di tawarkan? Transparansi biaya
- Dari mana raw material di dapatkan?

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 QUALITY ASSURANCE

2. Supplier Quality Assurance

Pemilihan supplier harus di dasarkan pada:

2. Technical and Quality Relates-aspects.

- Apakah supplier mampu memenuhi spesifikasi
- Konsistensi dari pemenuhan spesifikasi
- Apakah supplier sudah mengontrol potensial bahaya?

Semua supplier harus melalui proses seleksi, dan melalui audit,

sebelum dapat di setujui untuk menjadi supplier
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 LABORATORY

• Apakah fungsi laboratorium dalam system

Quality?

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 LABORATORY

ICP GLP

Laboratory memegang peranan kunci dalam Quality assurance

system oleh karena itu akurasi dan presisi dari hasil analisa harus
dapat di buktikan sebagai dasar kepercayaan dan pengambilan
keputusan.

Good Laboratory Practice harus diterapkan. (ref ISO 17025)

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 LABORATORY
Fungsi Laboratorium:
ICP
•Memastikan material yang masuk sesuai dengan GLP

spesifikasi
•Memastikan product yang dihasilkan memenuhi
spesifikasi yang ditetapkan
•Early warning system: melalui monitoring, analisa
lengkap, emerging issues (melamine, illegal preservative
etc.)
•Mengukur efektifitas dan performance dari Quality
System

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 SUMMARY
1. Apakah yang dimaksud dengan Quality?
2. Quality system mana yang terbaik?
3. Apa perbedaan antara Quality Control, Quality Assurance dan
Quality Mangement ?
4. Apakah yang di sebut makanan/minuman berkualitas
5. Hubungan antara GMP, HACCP dan Quality System. Manakah
yang harus di implementasikan terlebih dahulu?
6. Apakah sebelum ada HACCP, keamanan pangan di industri pangan
kurang baik?
7. Adakah bagian-bagian penting dalam business process yang
sangat menentukan kualitas produk akhir?
8. Apakah fungsi laboratorium dalam system Quality?

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 SUMMARY

• Thank you

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