O membro da sua equipe negligencia uma etapa crucial do controle de qualidade. Como você evitará defeitos de fabricação?

The first thing you should do quarantine any potential affected items and ensure ongoing production is properly inspected. Then either examine all quarantined items to ensure they are acceptable or dispose of them. The risk was unacceptable to begin with hence the crucial inspection requirement.

It happens several times as per my experience. First I will make sure if its a quality control step or there is a step missed in following SOP. Coming back to question, If its a step missed in following QC step, I will access the sample of products for quality check from the random population. A large random population have to be investigated for the probable defects based on previous reported data and few samples have to to given for complete quality check in a outside agency. Based on these outcomes, a unbiased decision have to to taken if the manufactured slot is competent or otherwise. SOP have to be accessed and revised in order to minimize this kind and other kinds of mistakes in future that altogether lead to deviation from SOP.

My action plan for such types of incidents are: 1- First step to identify and do correction immediately to prevent occurring defective products. 2- Immediately do the RCA (Root Cause Analysis) to avoid any reoccurrence. 3- Provide trainings to involved team or individuals. 4- After all RCA, revise procedures/Method Statement accordingly.

Una de las acciones correctivas para que no se pueda dar de nuevo una desviación es mediante herramientas informáticas generar controles de verificación que el operario y el personal de calidad se vean obligados a chequear para poder seguir adelante con la producción. Si se no se pueden utilizar herramientas informáticas se aumentarán las frecuencias de los controles ya marcados y se determinará si se deben implementar de nuevos.

Congratulations 👏 You have assumed that the missed step has been identified before it actually affected any process or product downstream. This represents an industrial process with excellent 👌 and full functional infrastructure. Immediate Action: Agreed with other respected Members Long-term action: Install and Enhance the detection system at locations (Material mines / source and mixing points) where you have control levers and provisions for giving immediate correction. And if possible make these corrections happen automatically using stringent process control protocols. But unfortunately in a typical industrial system the missed qc step appears badly either as process disturbance or as product defects 😂 discussion for someDAY

Treinar a equipe inteira, é claro, atualizar os pontos que foram avaliados, com o máximo de exemplos práticos e até estudos científicos teórico explicando detalhadamente o porque daquele passo ser tão importante para todo o processo.

1. Immediate containment. 2. Root cause analysis. 3. Reinforcement of procedures. 4. Implementing checks and balances. 5. Review and update SOPs. 6. Monitor and audit. 7. Feedback loop.

Training the team on the overall process is key and detailed training about a specific procedure in the production to the respective operator, which he has to be mindful about which may or may not coincide with other processes Take for example, an operator who handles the initial raw materials needs to be trained in sanitary handling and initial handling of the product, based on the sequence and quantity While the subsequent processing like the core temperature, cooking or any processing needs, to handled by the respective operators

Un plan de entrenamiento constante es fundamental, tanto para nuevos ingresos como para los más experimentados. Las tecnologías van cambiando, los equipos y los procesos se van actualizando. En mi experiencia tener mínimo un plan de capacitación y actualización dos veces al año es de alta importancia, nos permite que el personal vea practicas “comunes” que son erróneas y trabajemos en equipo para corregirlas.

Algo que he visto es que las capacitaciones muchas veces se realizan como parte de cumplimiento de check list de auditorías y muchas veces queda solo en "papel" y la verdadera naturaleza de la información no llega adecuadamente a los trabajadores involucrados en el proceso. Las capacitaciones deben ser desde la conciencia y el verdadero animo de aprender, de ejecutar y mejorar las practicas de manufactura

There's a provision when the HACCP Team or people working in the processing line meet occasionally to discuss the ongoing issue and the SOP's in place to counteract the issue If the system in place is not able to produce Notable results or the results shown are unsatisfactory, revision is needed and an alternate action plan needs to be in place These discussion will lead to further optimization of the SOP's

One thing that I found helpful is to traceback the process to find out what is the root cause of neglecting such important step. Then assess the risks associated, and implement effective corrective action which vary depending on the root cause. For example it could be retraining of the staff, system checks, or automation of some steps.

Entendo ser necessário em primeiro lugar encontrar a causa raiz do problema, feito isso, se for necessário o procedimento deve ser revisado e os colaboradores treinados novamente.

Generally, the organizations are reviewing the SOPs on regular basis and if there is a need to update the standard operating procedure, it is done.

A revisão do SOP (POP no Brasil), nesse caso de um membro estar negligenciando um passo importante para o controle de qualidade, só será viável após todas as verificações in loco se confirmarem sendo positivas para a rotina e não indique falha, isso tanto do ponto da tarefa do procedimento negligenciado, quanto o tamanho do impacto no final do processo, que se for melhorar deve ser revisado sim.

Checks are already implemented while designing the process flow. Increasing the number of the check/inspection/testing will not grantee the stable outcome.

Se o ponto negligenciado for importante a ponto de apresentar falha no controle de qualidade, devemos implementar com prioridade para o máximo de pontos do procedimento, afim de garantir que todos os passos estão sendo cumpridos, tanto pontos físicos como checklists, como também automatizar alguns alertas aos operadores se ignorarem. Reforçar ou criar um calendário de auditorias internas envolvendo a equipe e gestão devem ser implementadas o quanto antes.

En mi experiencia es fundamental dar con la causa raíz del problema y desde ahí implementar los suficientes controles. Pero todo esto va acompañado de una cultura organizacional que acompañe la mejora y que se involucre a toda la organización empezando por la alta dirección

It is the responsibility of the top leadership to develop a culture which is customer focused. For this purpose, share the data of customer complaints/NCs with the workers on regular basis. It is also recommended to have a competition among the different production lines/units to minimize the complaints or non-conformities.

Instilling a culture of following established protocols in the steps involved will lead to the elimination of negligence because it's part of one's workflow.

Sometimes it is challengeing to acheive the set goals or targets by the company. Adhering to tour KPIs in a managerial position requires the strenght of a good team work in order to succees. Resistamce to change is quite a tough game to play. So if you do not succed to convince other team members to work for the same target, a leader must influence. Set an example, and prosper the circle of influence. Communication, trust, honesty and transparency aligned with a pinch of emphaty support your actions. Ingrained culture and habits works miracles.

A qualidade do produto vem da forma que o processo realiza os passos, e se o operadores não estiverem engajados nessa cultura de qualidade, podem ser criados comemorações a cada meta de qualidade atingida.

Para esto, la empresa debe considerar a los trabajadores, desde el papel más sencillo hasta la alta directiva como eslabones de una cadena, todos los puestos son de importancia para lograr un producto final de calidad y seguro al consumidor

Negligence shouldn't be tolerated when it comes to the Quality of products. When it occurs first isolate the affected products and analyse the defects for immediate correction by taking the appropriate steps and retraining the staff on the need for continuous improvement and customer satisfaction to avoid future recurrence.

The policies or the FSMS in place are updating depending on the situation and food safety The protocol on the processing are also changing best suited to the particular industry, and each industry has its own vision for the product quality and safety the change in their policies are always micro managed and updated to stay with or ahead of the times For instance in some places for a microbial load parts per million (ppm) is considered standard some industries have taken a step further and consider parts per billion(ppb) as their standard that's their vision and goal on continuous improvement