Optimise A Quality Management System In A Food Or Sensitive Consumer Product Value Chain Training

Objectives:
• Understand the scope and importance of QMS in food and sensitive consumer product value chains.
• Identify key regulatory and standards frameworks (e.g., ISO 22000, FSSC 22000, SANS).
• Recognise the role of quality management in ensuring product safety and consumer protection.
• Describe the value chain concept and its relevance to quality optimisation.

Topics:
• Overview of quality management principles (ISO 9001, HACCP).
• Regulatory landscape: SAQA, NRCS, DoH, and international standards.
• The food and sensitive consumer product value chain: from raw materials to end consumer.
• Key stakeholders and their quality expectations.
• Introduction to unit standard 119798 and learning outcomes.
• Case study: Impact of poor quality in the value chain.

Objectives:
• Explain the core components of a QMS (policy, objectives, manuals, procedures).
• Differentiate between mandatory and voluntary standards.
• Understand document control and record-keeping requirements.
• Identify prerequisites for QMS certification.

Topics:
• QMS documentation hierarchy: policy, procedures, work instructions, records.
• ISO 22000:2018 and FSSC 22000 requirements.
• Prerequisite programmes (PRPs) and operational PRPs.
• Legal metrology and labelling requirements in South Africa.
• Document control: versioning, approval, and distribution.
• Exercise: Mapping QMS documentation for a selected product.

Objectives:
• Apply risk-based thinking to identify hazards in the value chain.
• Conduct a hazard analysis using HACCP principles.
• Determine critical control points (CCPs) and critical limits.
• Develop risk mitigation strategies.

Topics:
• Hazard categories: biological, chemical, physical, radiological, allergens.
• HACCP principles: from hazard analysis to verification.
• Risk assessment tools (e.g., FMEA, risk matrices).
• Establishing CCPs and setting critical limits.
• Monitoring and corrective actions for CCPs.
• Workshop: Conduct a hazard analysis for a selected product.

Objectives:
• Design monitoring systems for CCPs and quality indicators.
• Understand process validation and verification techniques.
• Implement traceability systems from raw materials to finished goods.
• Manage non-conformances and corrective actions.

Topics:
• Monitoring methods: temperature, pH, time, sensory.
• Calibration of monitoring equipment.
• Traceability: batch coding, lot tracking, recall procedures.
• Handling non-conformances: root cause analysis and CAPA.
• Revalidation and verification of processes.
• Practical: Develop a monitoring plan for a CCP.

Objectives:
• Evaluate and approve suppliers based on quality criteria.
• Establish incoming material inspection protocols.
• Manage supplier performance and audits.
• Ensure compliance with raw material specifications.

Topics:
• Supplier approval and qualification processes.
• Raw material specifications and certificates of analysis.
• Incoming inspection sampling plans (e.g., AQL).
• Supplier audits and performance scorecards.
• Managing supplier non-conformances.
• Case study: Supplier quality issues in a food value chain.

Objectives:
• Plan and conduct internal audits in accordance with ISO 19011.
• Report audit findings and follow up on corrective actions.
• Apply continuous improvement tools (PDCA, Kaizen, Six Sigma).
• Foster a culture of quality and employee involvement.

Topics:
• Internal audit programme management.
• Audit techniques: checklists, interviewing, sampling.
• Writing non-conformance reports and audit reports.
• Root cause analysis tools (5 Whys, fishbone diagram).
• Continuous improvement methodologies.
• Exercise: Conduct a mock internal audit.

Objectives:
• Identify relevant South African food legislation and regulations.
• Understand labelling, advertising, and food safety laws.
• Manage product recalls and withdrawals.
• Ensure compliance with international trade requirements.

Topics:
• Foodstuffs, Cosmetics and Disinfectants Act (Act 54 of 1972).
• Regulations R146, R429, and related amendments.
• Labelling requirements: allergens, nutritional information, claims.
• Recall management: planning, execution, communication.
• Export requirements: certificates, SPS measures.
• Workshop: Review product labels for compliance.

Objectives:
• Analyse QMS performance metrics and identify improvement areas.
• Integrate QMS with other management systems (e.g., OHS, environment).
• Use data-driven decision making to optimise quality.
• Develop a QMS optimisation plan.

Topics:
• Key performance indicators (KPIs) for quality: defect rates, customer complaints.
• Data analysis tools: control charts, Pareto analysis.
• Integrated management systems: ISO 9001, ISO 14001, ISO 45001.
• Cost of quality: prevention, appraisal, failure costs.
• Benchmarking and best practices.
• Project: Develop an optimisation plan for a QMS.

Objectives:
• Synthesise all learning into a comprehensive QMS optimisation strategy.
• Demonstrate competence through a practical assessment.
• Present and defend a QMS improvement project.
• Prepare for unit standard 119798 assessment.

Topics:
• Review of key concepts and integration.
• Practical assessment: QMS audit, risk analysis, or optimisation plan.
• Presentation of improvement projects.
• Peer and facilitator feedback.
• Assessment preparation and portfolio of evidence requirements.
• Course wrap-up and certification guidelines.