Manufacturing, Engineering and Technology Manufacturing and Assembly

Optimise Product And Process Quality In A Food Or Sensitive Consumer Product Environment Training

SAQA US 119800 | NQF 5 | Credits 8 | Duration 5 Days
From $1,242 per delegate

Description

This course equips learners with the competencies to optimise product and process quality in food or sensitive consumer product environments. Participants will learn to apply quality management principles, implement control measures, and drive continuous improvement to ensure compliance with industry standards.

Learning Outcomes

  • Analyse current product and process quality requirements against organisational standards and regulatory frameworks.
  • Design and implement quality control measures to monitor critical control points in production processes.
  • Evaluate the effectiveness of quality management systems using statistical process control and audit techniques.
  • Apply root cause analysis and corrective action procedures to address non-conformances and prevent recurrence.
  • Demonstrate continuous improvement methodologies (e.g., PDCA, Six Sigma) to optimise product and process quality.
  • Communicate quality performance data and improvement recommendations to relevant stakeholders.

Target Audience

Quality assurance managers, production supervisors, food safety practitioners, and technical staff responsible for maintaining product and process quality in food, beverage, cosmetics, or pharmaceutical manufacturing environments.

Prerequisites

None — open enrollment. However, learners should have access to a food or sensitive consumer product work environment for practical application.

Course Outline

Day 1: Foundations of Quality in Food and Sensitive Consumer Product Environments

Objectives:
• Understand the principles of quality management in food and sensitive consumer product industries.
• Identify key quality parameters for raw materials, in-process products, and finished goods.
• Explain the importance of Good Manufacturing Practices (GMP) and prerequisite programmes.
• Recognise the role of regulatory frameworks such as the Foodstuffs, Cosmetics and Disinfectants Act.
• Distinguish between quality control and quality assurance.

Topics:
• Introduction to quality concepts: definitions, dimensions, and importance
• Overview of regulatory requirements and standards (e.g., SANS, ISO 22000)
• Good Manufacturing Practices (GMP) and Sanitation Standard Operating Procedures (SSOPs)
• Key quality parameters: sensory, chemical, physical, and microbiological
• The food safety ecosystem: HACCP, traceability, and recall procedures
• Roles and responsibilities of quality personnel
• Case studies: quality failures in sensitive consumer products

Day 2: Statistical Process Control and Data Analysis for Quality

Objectives:
• Apply basic statistical tools to monitor and control product and process quality.
• Construct and interpret control charts for variables and attributes.
• Calculate process capability indices (Cp, Cpk) to evaluate process performance.
• Use cause-and-effect diagrams and Pareto analysis for problem solving.
• Analyse data to identify trends, shifts, and out-of-control conditions.

Topics:
• Introduction to statistical process control (SPC)
• Types of variation: common cause vs. special cause
• Control charts: X-bar and R charts, p-charts, c-charts
• Process capability analysis: Cp, Cpk, and interpretation
• Root cause analysis tools: fishbone diagram, 5 Whys, Pareto chart
• Practical exercises: manual plotting and using simple software
• Data collection plans and sampling strategies

Day 3: Process Optimisation and Continuous Improvement Methodologies

Objectives:
• Apply Lean and Six Sigma principles to reduce waste and variation.
• Conduct a process mapping and value stream analysis.
• Implement 5S methodology for workplace organisation.
• Use Kaizen events to drive incremental improvements.
• Develop key performance indicators (KPIs) for quality monitoring.

Topics:
• Overview of Lean manufacturing: waste identification and elimination
• Six Sigma methodology: DMAIC (Define, Measure, Analyse, Improve, Control)
• Process mapping: flowcharts and value stream mapping
• 5S: Sort, Set in order, Shine, Standardise, Sustain
• Kaizen: continuous improvement culture and tools
• Setting and tracking quality KPIs (e.g., defect rate, yield, customer complaints)
• Practical workshop: mapping a production process and identifying improvement opportunities

Day 4: Quality Management Systems and Auditing

Objectives:
• Describe the elements of a quality management system (QMS) per ISO 9001 or FSSC 22000.
• Understand the audit process: planning, conducting, reporting, and follow-up.
• Perform internal audits using checklists and objective evidence.
• Identify non-conformances and write effective corrective action requests.
• Integrate HACCP principles into the QMS.

Topics:
• QMS documentation: quality policy, manual, procedures, and records
• ISO 9001 and FSSC 22000 requirements specific to food/sensitive products
• Audit types: internal, external, third-party
• Audit planning: scope, criteria, and checklists
• Conducting audits: interviewing, observing, sampling
• Writing non-conformance reports and corrective action plans
• HACCP integration: critical control points, monitoring, verification
• Role-play: internal audit scenario in a food processing environment

Day 5: Practical Integration and Assessment

Objectives:
• Synthesise all course content to develop a quality improvement plan for a real-world scenario.
• Demonstrate competence in applying SPC, process optimisation, and auditing skills.
• Present findings and recommendations to peers for feedback.
• Complete a summative assessment covering theory and application.
• Reflect on personal learning and plan for workplace implementation.

Topics:
• Group project: quality improvement plan for a given product/process
• Presentation and peer review of improvement plans
• Summative assessment: written test and practical exercise
• Feedback session: lessons learned and best practices
• Action planning: how to apply skills on the job
• Course evaluation and certification process
• Q&A and closing remarks

Practicals

No practicals for this training.

This course is made up of exercises and case studies delivered alongside the theory — no separate practical sessions are required to complete it.

Summatives

Each delegate is assessed continuously throughout the course and a final summative test at the end.

Daily Exercises — 30%

Every training day ends with a multiple-choice exercise scored out of 100%. The scores from each daily exercise are averaged across the duration of the course to produce a Daily Average mark, which contributes 30% to the final total.

Final Test — 70%

On the last day a final summative test is written. It is a multiple-choice paper with multiple-answer questions: each question may have more than one correct option, and a single wrong selection on a question marks the entire question wrong — no partial credit. The final test is scored out of 100% and contributes 70% to the overall mark.

Final Total
Component Out of Weight
Daily Average (multiple choice) 100% 30%
Final Test (multi-answer multiple choice) 100% 70%
Final Total 100%

All marks are recorded on the AATICD LMS and visible to each learner under their account.

Certificate

Certificate of Completion

Awarded to delegates who achieve an overall mark of 50% or higher on the Final Total (Daily Average 30% + Final Test 70%).

How it works
  • Certificates are auto-generated on the AATICD LMS as soon as the marks pass the 50% threshold.
  • Each certificate is a branded PDF with the delegate's name, the course title, the unit standard ID, NQF level, credits, and the date of issue.
  • You can download or print your certificate from your LMS dashboard at any time after issue — there's no reissue fee and no expiry date.
  • If you scored under 50% you can sit the final test again at the next scheduled session at no extra cost.
Where to find it

Sign in to the LMS, open your dashboard, and your certificates appear under My Certificates. Each entry has a View / Download button and a print option.

Training Discounts

Group discounts apply automatically — the more delegates you enrol, the greater the saving. Discounts are calculated at 3% per 5 delegates, scaling up to 40% off for 100+ delegates.

Delegates Discount
5 3% off
10 6% off
15 9% off
20 12% off
25 15% off
30 18% off
50 30% off
75 35% off
100 40% off

3% discount per 5 delegates, up to 40% off for 100+ delegates. Contact us for a custom group quote.

Upcoming Training Sessions
Online training — attend live sessions from anywhere via our virtual classroom.
Start End Delivery Season Price Action
Mon 07 Sep 2026 Fri 11 Sep 2026 Virtual Spring 2026 $1,242 Register
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Mon 27 Dec 2027 Fri 31 Dec 2027 Virtual Summer 2027 $1,242 Register
Mon 17 Jan 2028 Fri 21 Jan 2028 Virtual Summer 2027 $1,242 Register
On-Campus training — face-to-face sessions at our training venues across Africa and beyond.
Showing all 492 sessions across 26 venues
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In-House training — we bring the trainer to your organisation, tailored to your team.
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Mon 14 Sep 2026 Fri 18 Sep 2026 Your Premises Spring 2026 $1,615 Register
Mon 05 Oct 2026 Fri 09 Oct 2026 Your Premises Spring 2026 $1,615 Register
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Mon 18 Jan 2027 Fri 22 Jan 2027 Your Premises Summer 2026 $1,615 Register
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Mon 08 Mar 2027 Fri 12 Mar 2027 Your Premises Autumn 2027 $1,615 Register
Mon 15 Mar 2027 Fri 19 Mar 2027 Your Premises Autumn 2027 $1,615 Register
Mon 22 Mar 2027 Fri 26 Mar 2027 Your Premises Autumn 2027 $1,615 Register
Mon 14 Jun 2027 Fri 18 Jun 2027 Your Premises Winter 2027 $1,615 Register
Mon 05 Jul 2027 Fri 09 Jul 2027 Your Premises Winter 2027 $1,615 Register
Mon 26 Jul 2027 Fri 30 Jul 2027 Your Premises Winter 2027 $1,615 Register
Mon 13 Sep 2027 Fri 17 Sep 2027 Your Premises Spring 2027 $1,615 Register
Mon 04 Oct 2027 Fri 08 Oct 2027 Your Premises Spring 2027 $1,615 Register
Mon 25 Oct 2027 Fri 29 Oct 2027 Your Premises Spring 2027 $1,615 Register
Mon 13 Dec 2027 Fri 17 Dec 2027 Your Premises Summer 2027 $1,615 Register
Mon 03 Jan 2028 Fri 07 Jan 2028 Your Premises Summer 2027 $1,615 Register
Mon 24 Jan 2028 Fri 28 Jan 2028 Your Premises Summer 2027 $1,615 Register
Training Discounts
Delegates Discount
5 3% off
10 6% off
15 9% off
20 12% off
25 15% off
30 18% off
50 30% off
75 35% off
100 40% off

3% off per 5 delegates, up to 40% for 100+

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