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HACCP Verification TaskAssociating NRs Workshop:

Open Beef9-08-2012

Inspection Methods 1

HACCP Verification Task - Associating NRs Workshop:Open Beef

General Instructions

Work through this workshop with a partner. Read the workshop scenario and thereference 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 andprocessing 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 theInspection Methods course, that before you perform a task you need to review theestablishments HACCP plan to familiarize yourself with the monitoring procedures andfrequencies, 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 isprovided 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 lacticacid monitoring record at the final wash CCP 5B. You review the results he has enteredon the lactic acid record since the beginning of the shift.

Workshop Questions

After reviewing Open Beefs HACCP plan and the lactic acid monitoring record onpages 3 through 9 answer the following questions.

1. Has a noncompliance occurred based on reviewing the lactic acid monitoringrecord? 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?

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HACCP Verification TaskAssociating NRs Workshop:

Open Beef9-08-2012

Inspection Methods 2

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 notcome in today and he was performing all of the sanitary dressing prerequisite programchecks and the other CCP monitoring. You then notified the HACCP Coordinator,Melvin Sharp, of the failure to conduct the lactic acid concentration check at thefrequency listed in the HACCP plan. Mr. Sharp says that he will identify additionalemployees and train them so they can conduct monitoring activities when needed. Youobserved Mr. Sharps measures to ensure that product produced at the time of themissed monitoring check was safe.

As you prepare to document of the noncompliance in PHIS, you recall that you hadnearly the same results last week, you reviewed the previous NR and the further

planned action that was provided by establishment management was Mr. Smith, themonitor assigned to this station, was counseled on the importance of performing themonitoring checks at the frequency listed in the HACCP plan. You decide that thesetwo noncompliances have the same cause, and that the further planned actions takenlast week have not been effective in preventing the noncompliance from recurring.

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Inspection Methods 3

Establishment Name: Open BeefSlaughter and Raw Intact/Raw Non-intact Product HACCP Plan

(Beef carcasses, primals and subprimals, trimmings, edible offal and

AMR product)

CCPNumber

CriticalLimit

MonitoringProcedures

HACCPRecords

VerificationProcedures

CorrectiveActions

1BHeadProcessing/Boning

Product willmeet theacceptableFood SafetyStandard(No visiblefeces,

ingesta ,ormilk)

QA personnel willmonitor the zerotolerance / FSSCCP by visuallyinspecting 60 lbsof cheek meat,head meat and

weasand meat (atthe time ofpackaging) arefree from visiblefecal ingesta ormilk at the QAinspection areaonce perproduction period(every 2 hours)and document the

result on the Zerotolerance /FSSMonitoring Log -Heads

Zerotolerance/FSS Monitoring/ verificationLog - Heads

Corrective

Action Log

Documentationverification iscompletedonce per shiftand recordedon the Zerotolerance/FSS

Monitoring Log- Heads.

Directobservation ofthe monitoringactivities iscompletedonce perproduction

week andrecorded onthe Zerotolerance/FSSMonitoringLog - Heads

Per 417.3QApersonnelareresponsiblefor assuringthat

correctiveactions aretaken.

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HACCP Verification TaskAssociating NRs Workshop:

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Inspection Methods 4

CCPNumber

CriticalLimit

MonitoringProcedures

HACCPRecords

VerificationProcedures

CorrectiveActions

2B

HeadProcessing/Boning

Surface of

heads andtonguesmust berinsed orsprayedwith asolutionthat is 2% lacticacid with 10 psi.

Once per

productionperiod (every 2hours) QApersonnel willmeasure thelactic acidconcentrationby using anorganic acidtest kit anddocument theresult on CCP2B HeadProcessingMonitoring Log

Also once perproductionperiod (every 2hours) QApersonnel willvisuallymonitor thelactic acidpressuregauge anddocument theresult of thereading onCCP 2B HeadProcessingMonitoring Log

Head

SprayMonitoringLog

CorrectiveAction Log

Documentation

verification iscompleted onceper shift andrecorded onCCP 2B HeadProcessingMonitoring Log

Directobservation ofthe monitoringactivities iscompleted onceper productionweek, andrecorded onCCP 2B HeadProcessingMonitoring Log

Per 417.3

QApersonnelareresponsiblefor assuringthatcorrectiveactions aretaken

.

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HACCP Verification TaskAssociating NRs Workshop:

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Inspection Methods 5

CCPNumber

CriticalLimit

MonitoringProcedures

HACCPRecords

VerificationProcedures

CorrectiveActions

3B

VisceraProcessing

Surface of

visceralorgansmust berinsed orsprayedwith asolution oflactic acid 2% with

10 psi.

Once per

productionperiod (every 2hours) QApersonnel willmeasure thelactic acidconcentrationby using anorganic acidtest kit anddocument theresult on theViscera SprayMonitoringLog

Also once perproductionperiod (every 2hours) QApersonnel willvisuallymonitor thelactic acidpressuregauge anddocument theresult of thereading on theViscera SprayMonitoringLog

Viscera

SprayMonitoringLog

CorrectiveAction Log

Documentation

verification iscompleted onceper shift andrecorded on themonitoringdocument.

Directobservation ofthe monitoringactivities iscompleted onceper productionweek.

Per 417.3

QApersonnelareresponsiblefor assuringthatcorrectiveactions aretaken.

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HACCP Verification TaskAssociating NRs Workshop:

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Inspection Methods 6

CCPNumber

CriticalLimit

MonitoringProcedures

HACCPRecords

VerificationProcedures

CorrectiveActions

4B

Trim Rail

Carcass

will meettheacceptableFoodSafetyStandard(No visiblefeces,ingesta, ormilk)

Once per

productionperiod (every 2hours) beforethe washcabinet QApersonnel willvisuallyinspect Threecarcasses (6sides) for ZeroTolerancerequirements(No feces,ingesta, and/ormilk) anddocument theresult of themonitoring onthe FSSMonitoringLog-Carcasses

FSS

MonitoringLogCarcasses

CorrectiveAction Log

Documentation

verification iscompleted onceper shift andrecorded on themonitoringdocument.

Directobservation ofthe monitoringactivities iscompleted onceper productionweek.

Per 417.3

QApersonnelareresponsiblefor assuringthatcorrectiveactions aretaken.

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HACCP Verification TaskAssociating NRs Workshop:

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Inspection Methods 7

CCPNumber

CriticalLimit

MonitoringProcedures

HACCPRecords

VerificationProcedures

CorrectiveActions

5BFinalWash

Surface ofcarcassesmust berinsed orsprayed witha solutionthat is 2%lactic acidwith 10 psi.

Once perproductionperiod (every 2hours) QApersonnel willmeasure thelactic acidconcentrationby using anorganic acidtest kit and

document theresult on CCP5B CarcassSprayMonitoring Log

Also once perproductionperiod (every 2hours) QApersonnel willvisually monitor

the lactic acidpressuregauge anddocument theresult of thereading onCCP 5-BCarcass SprayMonitoring Log

Carcass SprayMonitoring Log

CorrectiveAction Log

Documentationverification iscompletedonce per shiftand recordedon themonitoringdocument.

Directobservation of

the monitoringactivities iscompletedonce perproductionweek andrecorded onthe monitoringdocument

Per 417.3QApersonnelareresponsibleforassuringthatcorrectiveactions aretaken.

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HACCP Verification TaskAssociating NRs Workshop:

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Inspection Methods 8

Melvin Sharp March 4, 2010 Revised--August 24, 2011 Melvin Sharp

Reassessed: February 10, 2011 Melvin SharpReassessed: February, 1, 2012 Melvin Sharp

CCPNumber

CriticalLimit

MonitoringProcedures

HACCPRecords

VerificationProcedures

CorrectiveActions

6B

Chilling

The surface

temperatureofcarcasses,edible offal,and meatderived fromheads will be 40F within24 hoursfrom the timeon the scaleticket.

Who:

Refrigerationmaintenancepersonnel

What: themidline surfacetemperature of10 carcasses,10 pieces ofedible offal and10 pieces ofmeat derivedfrom heads willbe randomlyselected andmonitored

When: within24 hours fromthe time of thescale ticket.

Where: In eachhot box andoffal coolerbeing used forcurrentproduction.How: acalibratedthermometerwill be used tomeasure thesurfacetemperature

Carcass

TemperatureMonitoring Log

ThermometerCalibrationLog

CorrectiveAction Log

Documentation

verification iscompletedonce per shiftand recordedon themonitoringdocument.

Directobservation ofthe monitoringactivities iscompletedonce perproductionweek.

Thermometercalibrationverification isperformed dailyand the resultis documentedon thethermometercalibration Log.

Per 417.3

QApersonnelareresponsibleforassuringthatcorrectiveactions aretaken.

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HACCP Verification TaskAssociating NRs Workshop:

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Inspection Methods 9

Open Beef: CCP 5B Carcass Wash Lactic Acid Monitoring Log

Date: 2-2-2012

Time LotNumber

SolutionConcentration

PSI CorrectiveActions

Monitored by Verified by/result

6:30 am 101 2.4 13 - SS

10:40 am 101 2.3 12 - SS

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HACCP Verification TaskAssociating NRs Workshop:

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Inspection Methods 10

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 furtherinstructions, consult the PHIS Quick Reference Guide.

Logging in to PHIS

1. Log-in as:

User Name: FSIS_user

Password: FSIS

2. If needed, start Internet Explorer using the Icon on upper left of the desktop:

Double click the Internet explorer ( ) icon

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 SlaughterHACCP 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 thedown 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 aroutine 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 Addlink for the

Slaughter HACCP verification task

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Inspection Methods 11

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 theSave button

Initiate/Claim the HACCP Verification Task

1. Scroll down to the Task Calendar panel, left click thedown arrow in the box

next to Establishment that has the word all and selectOpen 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 theradio 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 thedown arrow in the box

next to Establishment that has the word all and selectOpen Beef

2. Right click on the Slaughter HACCP verification task on the calendar

3. Highlight and left clickDocument

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