Statistical Process Control for the Food Industry

SARINA ABDUL HALIM LIM is part of the Faculty of Food Science and Technology, Universiti Putra Malaysia, Malaysia. Sarina is currently pursuing research on SPC implementation in the food industry. Sarina has also taught several modules on SPC and DOE for process analysis and optimization.
 
JIJU ANTONY works at the School of Social Sciences at Heriot-Watt University, Edinburgh, UK. He is recognized as a leader in Six Sigma methodology for achieving and sustaining process excellence, and delivers training courses on quality management, process management, and Lean Six Sigma topics to numerous companies world wide.

A comprehensive treatment for implementing Statistical Process Control (SPC) in the food industry
 
This book provides managers, engineers, and practitioners with an overview of necessary and relevant tools of Statistical Process Control, a roadmap for their implementation, the importance of engagement and teamwork, SPC leadership, success factors of the readiness and implementation, and some of the key lessons learned from a number of food companies. Illustrated with numerous examples from global real-world case studies, this book demonstrates the power of various SPC tools in a comprehensive manner. The final part of the book highlights the critical challenges encountered while implementing SPC in the food industry globally.
 
Statistical Process Control for the Food Industry: A Guide for Practitioners and Managers explores the opportunities to deliver customized SPC training programs for local food companies. It offers insightful chapter covering everything from the philosophy and fundamentals of quality control in the food industry all the way up to case studies of SPC application in the food industry on both the quality and safety aspect, making it an excellent "cookbook" for the managers in the food industry to assess and initiating the SPC application in their respective companies.
* Covers concise and clear guidelines for the application of SPC tools in any food companies' environment
* Provides appropriate guidelines showing the organizational readiness level before the food companies adopt SPC
* Explicitly comments on success factors, motivations, and challenges in the food industry
* Addresses quality and safety issues in the food industry
* Presents numerous, global, real-world case studies of SPC in the food industry
 
Statistical Process Control for the Food Industry: A Guide for Practitioners and Managers can be used to train upper middle and senior managers in improving food quality and reducing food waste using SPC as one of the core techniques. It's also an excellent book for graduate students of food engineering, food quality management and/or food technology, and process management.

Preface xiii
 
1 Quality Management in the Food Industry 1
 
1.1 Introduction 1
 
1.2 Definition of Quality Control 1
 
1.3 Quality Control in the Food Industry 2
 
1.3.1 Quality Control (Raw Material) 3
 
1.3.2 Quality Control in Production (Processes and End Product) 4
 
1.3.3 Issues Related to the Quality Control 6
 
1.3.3.1 Late Adopters 6
 
1.3.3.2 Difficulties Identifying and Prioritising Hazards (Microbiological and Chemical) 6
 
1.3.3.3 Lack of Scientific and Quantitative Method to Assess Critical Points 6
 
1.4 Quality Assurance 7
 
1.4.1 Current Good Manufacturing Practice (cGMP) 7
 
1.4.2 HACCP (Hazard Analysis of Critical Control Point) 8
 
1.4.3 ISO 9
 
1.4.4 British Retail Consortium 9
 
1.5 Quality Management System in the Food Industry 9
 
1.6 Statistical Thinking 10
 
1.7 Summary 12
 
2 Food Industry and its Contribution to the Global Economy 13
 
2.1 Introduction 13
 
2.2 What Is the Role of Food Industry in the Global Context? 14
 
2.3 Several Classifications of Food Industry from Several Sources 15
 
2.4 How is the Food Industry Different from Other Industries? 18
 
2.5 Customers and Consumers 19
 
2.6 Government Plan 20
 
2.7 Summary 20
 
3 Quality and Safety in the Food Industry 23
 
3.1 Introduction 23
 
3.2 Food Quality 25
 
3.2.1 Objective and Subjective Quality 25
 
3.3 Food Safety 27
 
3.4 Hazard Analysis and Critical Control Point (HACCP) 28
 
3.4.1 Concept 28
 
3.4.2 HACCP Principles 30
 
3.4.2.1 Principle 1 30
 
3.4.2.2 Principle 2 30
 
3.4.2.3 Principle 3 30
 
3.4.2.4 Principle 4 30
 
3.4.2.5 Principle 5 31
 
3.4.2.6 Principle 6 31
 
3.4.2.7 Principle 7 31
 
3.4.3 Hazards 32
 
3.4.3.1 Physical Contamination 32
 
3.4.3.2 Chemical Contamination 33
 
3.4.3.3 Microbiological Contamination 33
 
3.4.4 Documentation 34
 
3.4.5 Critical Control Point (CCP) 34
 
3.4.6 How to Do it? 34
 
3.4.6.1 Step 1: Develop HACCP Team 34
 
3.4.6.2 Step 2: Describe and Characterise the Product 35
 
3.4.6.3 Step 3: Construct the Process Flow Diagram 36
 
3.4.6.4 Step 4: Identify the Hazards Control 36
 
3.4.6.5 Step 5: Quantify and Analyse the Hazards 36
 
3.4.6.6 Step 6: Identify Control Requirements, Targets and Tolerances 37
 
3.4.6.7 Step 7: Identify CCPs and Assess Existing Controls 37
 
3.4.6.8 Step 8: Establish a Monitoring System for Each CCP 38
 
3.5 Good Manufacturing Practice 38
 
3.5.1 Personnel 39
 
3.5.2 Plant and Grounds 39
 
3.5.3 Sanitary Operation 40
 
3.5.4 Sanitary Facilities and Controls 40
 
3.5.5 Equipment and Utensils 40
 
3.5.6 Processes and Controls 40
 
3.5.7 Raw Materials 40
 
3.5.8 Warehousing and Distribution 41
 
3.6 Food and Drug Administration (FDA) 42
 
3.7 Summary 42
 
4 An Introduction of SPC in the Food Industry: Past, Present and Future 43
 
4.1 Statistical Process Control: A Brief Overview 43
 
4.2 Quality Control in the Food Industry: Before SPC 44
 
4.2.1 Inspection! Inspection! Inspection! 45
 
4.3 The Evolution of SPC in the Food Industry 48
 
4.4 The Principle of Current Quality Control 50
 
4.4.1 Control in Raw Material 50
 
4.4.2 Control in the Finished Product 51
 
4.4.3 Control in Processing 51
 
4.4.4 The Practicality of SPC in the Food Indus

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