1. Good Hygiene Practices along the coffee chain Establish Corrective Actions (Task 10 / Principle 5) Module 4.10

2. Slide 2 Module 4.10 – Establish Corrective Actions (Task 10 / Principle 5) Objectives and contents  Objectives  To enable trainees to establish effective procedures for corrective actions when there are deviations from critical limits  Contents  What is ‘process deviation’ and ‘loss of control’?  Scope of deviation procedures / corrective action  Deviation and corrective action records

3. Slide 3 Module 4.10 – Establish Corrective Actions (Task 10 / Principle 5) Corrective action Where loss of control is  A deviation from a critical limit Corrective action...any action to be taken when the results of monitoring at the CCP indicate a loss of control

4. Slide 4 Module 4.10 – Establish Corrective Actions (Task 10 / Principle 5) Proactive nature of HACCP  In HACCP plans deviation procedures are pre-determined and documented actions to be implemented in case of a deviation  Control of non-compliant product  Addressing source of problem within the process  Trend of deviation from operating limits adjustments to prevent loss of control

5. Slide 5 Module 4.10 – Establish Corrective Actions (Task 10 / Principle 5) Corrective actions  Depending on the process, several deviations may be possible at a CCP  More than one corrective action may be required for each CCP  Individuals responsible for monitoring must be trained to adequately perform corrective actions when necessary

6. Slide 6 Module 4.10 – Establish Corrective Actions (Task 10 / Principle 5) Product deviation – controlling non-compliant product  Process deviation is ‘failure to meet critical limit’  A deviation implies that a safety breach has occurred Immediate action  Activates a system that identifies, marks and isolates all product affected over the deviation period  Producer must maintain control of suspect batch pending evaluation Deferred action  The evaluation establishes the status of the batch regarding safety - to release, reprocess, or destroy

7. Slide 7 Module 4.10 – Establish Corrective Actions (Task 10 / Principle 5) Deviation procedures – controlling cause of deviation  Investigation to determine the cause of deviation  Determine if measures can be taken to prevent recurrence of the deviation  Possible re-evaluation of aspects of the HACCP plan or related hazard analysis  Verify that the corrective action was effective

8. Slide 8 Module 4.10 – Establish Corrective Actions (Task 10 / Principle 5) Form 10 - documenting deviation processes in the HACCP plan Process step CCP No. Hazard description Critical limitsMonitoring procedures Deviation procedures HACCP records 6. Boia sun- drying CCP1 a (B) Long residence time in a partially dried condition can allow development of mould and production of OTA 5 days or less between A w 0.95 and 0.80 A w / m.c. measurement nightly from day 3 Sequester; complete drying in mechanical dryer; OTA testing A w / m.c. records; lab reports; CCP1 b (B) Reintroduction of water after drying mostly accomplished can lead to growth of mould No exposure to condensation at night; No exposure to rain Continuous visual assessment of weather conditions; inspection of covering of coffee in the evening Continue drying; measure A w / m.c. at end of day; apply CCP1a specification Rainfall records; drying yard records

9. Slide 9 Module 4.10 – Establish Corrective Actions (Task 10 / Principle 5) Deviation records  Accurate records of deviations are essential  Demonstrate effective control of affected products  Facilitate system improvements  Deviation records include  Product affected Product / code; date produced / held / released; reason for holding; amount of product affected; details of evaluation; signature of staff taking or approving action  Corrective action Cause of deviation; action taken; follow-up

10. Slide 10 Module 4.10 – Establish Corrective Actions (Task 10 / Principle 5) Deviation records RECORD OF DEVIATION PROCEDURES AND CORRECTIVE ACTIONS DOMAIN OF APPLICATION (Area or stage of production line involved)CODE: DESCRIPTION OF THE DEVIATIONReporting Staff: Date: Signature: Confirmation: Yes / No Date: Signature: IMMEDIATE ACTION Product Process Responsible staff: Date: Signature: Verified by: Date: Signature: DEFERRED ACTION Evaluation of affected product Responsible staff: Date: Signature: Analysis of the cause of the deviationResponsible staff: Time/Date: Decision regarding actionApproving staff: Date: Signature: Implementation of actionResponsible staff: Time/Date: Efficacy of corrective actionConfirmation: Yes / No Date: Signature:

11. Slide 11 Module 4.10 – Establish Corrective Actions (Task 10 / Principle 5) Dealing with process deviations  Deviation procedures cannot be generalized - they depend on products and production methods  However, identification and isolation of affected product for evaluation is the first step  Deviations may arise from mechanical faults, procedural oversights or, in some cases, external specification violation  Follow-up might include plant renewal, staff retraining, education of suppliers

12. Slide 12 Module 4.10 – Establish Corrective Actions (Task 10 / Principle 5) Summary  Deviation and corrective action procedures  Documenting corrective actions in a HACCP plan  Deviation records Next module: Establish verification procedures