FSSC 22000 Version 5.1 – Complete Documentation Kit

The contents of the FSSC 22000 scheme version 5.1 document kit include more than 170 files in 9 directories as listed below:

• FSSC 22000 Manual (14 files): A sample food safety manual with a food safety policy that meets the requirement of FSSC 22000 version 5.1 certification.
• FSSC Procedures (14 procedures): It includes 14 FSSC 22000 procedures to implement the system in the company and comply with food safety management system requirements.
• Exhibits (13 exhibits): The 13 exhibits including an exhibit for skill requirements, Quality plan – incoming inspection and testing, etc are given.
• Standard Operating Procedures (30 SOPs): It covers a sample copy of standard operating procedures as per FSSC 22000 (version 5.1).
• Process Approach (10 process approaches): It covers process approaches designed as per the latest version 5.1 of FSSC 22000 scheme.
• Blank Forms and Templates (70 sample forms): A set of 70 sample templates and standard forms to demonstrate the implementation of a food safety system as per scheme version 5.1.
• HACCP Documents (18 documents): It covers product description, process flow chart, hazards analysis report, HACCP plan, corrective action plan, etc. documents
• FSSC 22000 Audit checklist (more than 800 questions): Requirement wise FSSC 22000 audit checklist and Department wise FSSC 22000 audit questions that can be easily customizable for making your own audit checklists for effectively auditing as per FSSC 22000 version 5.1.
• FSSC 22000 Version-5.1 Compliance Matrix (01 MS Excel File): This document contains FSSC 22000 Version-5.1 requirement wise list of documented information for easy reference of users and to understand how this system is made.

All the FSSC 22000 version 5.1 documents provided are editable and the users can easily modify the name of the company, its logo and other details required for their company during the preparation of FSSC 22000 documents as per scheme version 5.1.

Documented information package:

Our documentation kit comprises sample documents required for FSSC 22000 Version 5.1 packaging materials certification as listed below. All documents are in MS Word / Excel format and you can edit them. You can make changes as per your company’s needs and within few days your entire documents with all necessary system requirements can become ready. In the FSSC 22000 Version 5.1 packaging materials, at few places, documented information are required. But for making the system better, we have provided many editable templates from which a user can select and make some minor changes to make own system. Now, FSSC 22000 Version 5.1 packaging materials standard does not require manual, procedures, etc. It requires two types of documented information as listed below:

1. Maintain documented information (Scope, Product Safety Manual, etc.)
2. Retain documented information (Forms / Templates)

Under the given directories, further files are provided in MS word/excel document as per the details given below. All the documents are related to food manufacturing / process industry.

1. Product Safety Manual (10 Chapters and 4 Annexure):

This is a sample copy of product safety manual which gives clause-wise details of how FSSC 22000 version 5.1 system is implemented. It covers the food safety management system, sample
food safety policy, objectives, scope, organization structure as well as how each requirement from clause no. 4 to 10 of FSSC 22000 version 5.1 is implemented at macro level in the organization.
The manual covers FSSC 22000 version 5.1 documents for tier-1 of documented information. It has total 10 chapters covering company profile, amendment sheet, index, and clause-wise details on how FSSC 22000 version 5.1 system is implemented in an organization.
(A) Table of Contents
Section – 1
1. Company profile
2. Table of contents
3. Control and distribution
Section – 2
4. Context of the Organization
4.1 Understanding the organization and its context
4.2 Understanding the needs and expectations of interested parties
4.3 Determining the scope of the quality management system
4.4 Product safety management system
Additional FSSC requirements
5. Leadership
5.1 Leadership & Commitment
5.2 Policy
5.3 Organizational roles, responsibilities and authorities
6. Planning
6.1 Action to address risks and opportunities
6.2Objectives of the product safety management system and planning to achieve them
6.3 Planning of changes
7. Support
7.1 Resources
7.2 Competence
7.3 Awareness
7.4 Communication
7.5 Documented information
8. Operation
8.1 Operational planning and control
8.2 Pre-requisite programs (PRPs)
8.3 Traceability system
8.4 Emergency preparedness and response
8.5 Hazard control
8.6 Updating the information specifying the PRPs and the hazard control plan
8.7 Control of monitoring and measuring
8.8 Verification related to PRPs and the hazard control plan
8.9 Control of product and process nonconformities
9. Performance evaluation
9.1 Monitoring, measurement, analysis and evaluation
9.2 Internal audit
9.3 Management review
10. Improvement
10.1 Nonconformity and corrective action
10.2 Continual improvement
10.3 Update of the product safety management system
Annexures
ANX–I List of documented information
ANX–II Glossary of terms
ANX–III Company activity process flow chart
ANX–IV Organization structure

2. Quality and Product Safety Procedures (14 procedures):

Sample copies of mandatory procedures as per FSSC 22000 version 5.1 are provided, which cover all the details like purpose, scope, responsibility, how procedure is followed as well as the list
of exhibits, reference documents and formats. The list of sample procedures provided in the kit is as below.

List of Procedures

1. Procedure for preliminary analysis of production process
2. Procedure for pre-requisite program
3. Procedure for hazard identification
4. Procedure for HACCP plan
5. Procedure for emergency preparedness and response
6. Procedure for product withdrawal & recall
7. Procedure for management review
8. Procedure for document and data control
9. Procedure for correction, corrective and preventive action
10. Procedure for control of records
11. Procedure for internal audit
12. Procedure for control of monitoring and measuring equipments
13. Procedure for communication
14. Procedure for control of non-conforming products

3. Exhibits (14 exhibits)

The exhibits given in this kit are sample copies of exhibits as per FSSC 22000 version 5.1 for packaging materials. The list of sample exhibits provided is as below.

List of Exhibits

1. Exhibits for Skill requirements
2. Exhibits for Disposal of non–conforming products
3. Exhibits for Quality plan – Incoming inspection and testing
4. Exhibits for Raw material specifications
5. Exhibits for Codification system
6. Exhibits for Needs and expectation of the interested parties
7. Exhibits for Communication matrix
8. Exhibits for Risk analysis
9. Exhibits for Cleaning and sanitization schedule
10. Exhibits for Security assessment
11. Exhibits for Threat assessment
12. Exhibits for Threat assessment plan
13. Exhibits for Vulnerability assessment
14. Exhibits for Vulnerability assessment plan

4. Standard Operating Procedures (24 SOPs):

The SOPs given in this kit are sample copies of standard operating procedure as per FSSC 22000 version 5.1 for packaging materials. The list of sample standard operating procedures provided is as below.

List of Standard Operating Procedures

1. SOP for Glass breakage management
2. SOP for Waste disposal
3. SOP for Self care laundering
4. SOP for Cleaning and sanitation of Product contact surface
5. SOP for Hygiene clearance
6. SOP for Purchasing
7. SOP for Incident reporting
8. SOP for Metal, wood & glass, brittle plastics management procedure
9. SOP for Entry / Exit procedure – Personal hygiene
10. SOP for Pest control
11. SOP for Wooden materials
12. SOP for Personnel health and hygiene
13. SOP for Material receipt / issue in dispatch
14. SOP for Product information, consumer awareness and food defense
15. SOP for RM / PM / general material receipt / issue / storage
16. SOP for Product defense
17. SOP for Purchase of packing materials
18. SOP for Building maintenance and general facilities
19. SOP for Construction and layout of the building
20. SOP for Material / process / product mix-up
21. SOP for confidential reporting Channel
22. SOP for General housekeeping
23. SOP for Air, water, energy, gas and boiler chemical
24. SOP for Product fraud prevention

5. Process approach (11 process templates)

The templates given under this directory cover guidelines for processes, process flow charts and process models useful for process mapping. They cover activities of all the main and critical processes as listed below with input-output matrix for organization. The process templates help any organization in process mapping as well as preparing process documents. In Input-output matrix input and output documents as well as their inter-linkage with other departments are given.

List of Process Flow Chart

1. Process flow chart of customer service
2. Process flow chart of dispatch
3. Process flow chart of engineering
4. Process flow chart of marketing
5. Process flow chart of production
6. Process flow chart of purchase
7. Process flow chart of quality control
8. Process flow chart of PSTL processes
9. Process flow chart of stores
10. Process flow for training activity
11. Process flow for design and development

6. Blank sample formats for all the departments (61 sample formats)

This directory includes sample copy of blank forms that are required to maintain records as well as establish control and create system in the organization. The samples are given for the users as a guide to follow. The organization is free to change the same to suit their own requirements. The blank formats can be used as templates. A total of 61 blank formats are provided as per the list given below.

List of blank formats

1. Loading vehicle checking report
2. Validation report
3. Breakdown history card
4. Order form confirmation
5. Preventive maintenance schedule
6. Feedback for customer
7. Preventive maintenance checkpoints
8. Customer complaint report
9. Daily Preventive Maintenance checkpoints
10. Design and development records
11. Preventive Maintenance checkpoints for building and civil work
12. Daily stock Statement
13. Incident reporting record
14. Gate pass
15. Temporary maintenance work report
16. Unloading vehicle checking report
17. Cleaning and sanitation report
18. Master list cum distribution list of documents
19. House keeping records–area wise
20. Change note
21. Visitor entry report
22. Corrective action report
23. Pest control report
24. Master list of records
25. Fly-Kill Machine Cleaning Record
26. Objectives
27. Daily sanitation audit report
28. Audit plan/ schedule
29. Weekly Surveillance Audit for Dress Code
30. Internal audit non conformity report
31. Glass inventory records
32. Clause wise document wise audit review report
33. Suggestion Box Verification record
34. Magnet control
35. Wooden checking
36. Continual improvement plan
37. Rodent trapping record
38. Calibration status of instrument
39. Operation pre-requisite programs
40. Communication report
41. Daily Personnel Hygiene Checklist
42. List of chemicals on site
43. Medical checkup report
44. Food defense check list
45. Production planning
46. Monthly product safety inspection report
47. Disposal of non confirming products
48. Mock drill report
49. Purchase order
50. Training calendar
51. Indent cum Incoming Inspection
52. Training report
53. Approved vendor list cum open purchase order
54. Induction training Report
55. Supplier registration form
56. Job description and specification
57. Open purchase order
58. Skill matrix
59. Supplier audit schedule
60. Health questionnaire
61. Supplier audit checklist

7. HACCP Documents

This directory of the kit includes blank and filled HACCP documents on Product Description, Process flow chart, Hazard Analysis Report, HACCP Plan, Corrective Action Plan, Environment Monitoring Plan, Operation Pre-requisite Programs, Pre-requisite Programs, etc.

8. FSSC 22000 Version 5.1 for packaging materials Audit Checklists (More than 800 Questions)

In total three checklists comprising FSSC 22000 version 5.1 packaging materials requirements wise as well as department wise audit questions as well as self audit questions are provided. These checklists will be a very good tool for the auditors to make audit questionnaire for auditing. It will bring effectiveness in auditing. The questions are prepared on the basis of FSSC 22000 version 5.1 packaging materials. It can be logically used for auditing during internal audit for FSSC 22000 version 5.1 to establish proper audit trail.

9. FSSC 22000 Version 5.1 packaging materials compliance matrix

This compliance matrix contains FSSC 22000 version 5.1 packaging materials requirement wise list of documented information for easy reference of users and to understand how this system is
made.