2.1 Variables to Specifications

Reducing variation in both ___ and ___ is a primary means of decreasing product defects and improving product quality.

• key product features

• manufacturing processes

What are the variables in food processing?

1. raw materials and ingredients

2. machines

3. methods

4. manpower

True or False: Verbal agreements are sufficient for producers to deliver raw materials to the food industry.

False. To establish raw material needs, requirements must be written down. Producers are required to deliver according to written specifications.

True or False: Raw materials used in the food industry must comply strictly with FDA regulations and be of food-grade quality.

True

True or False: Manufacturers do not need to disclose the individual components of their ingredient formulations as long as the final product is safe.

False. Manufacturers must supply the food firm with a written detailed list of all individual components used in their formulation to ensure full compliance with laws and regulations

True or False: For supplier certification, a well-developed quality plan requires proper documentation to support its process control schemes.

True. Certification of Suppliers mandates a quality plan with process controls to assure finished materials, which must be backed by proper documentation.

True or False: Certified suppliers are expected to maintain current standards but are not required to adopt continuous improvement.

False. A core requirement for the Certification of Suppliers is that they must understand and apply the philosophy of continuous improvement.

True or False: Incoming materials at a food plant can be accepted based on general industry standards even if they slightly deviate from the company's specific criteria.

True. All materials coming into a food plant must be accepted only on the basis of meeting the company's given specifications, defined as Acceptable Quality Levels (AQL).

True or False: It is mandatory that all incoming materials are carefully sampled and analyzed upon arrival at the food plant.

True

True or False: Machines in food processing can operate under variable, undefined parameters as long as they perform their intended unit operations.

False. While machines are designed to perform specific functions or unit operations, they must be operated under specific parameters. This precision is required to ensure the proper effect on product quality.

True or False: The food-contact surfaces of a machine can react slightly with the food product during normal processing conditions.

False. Food-contact surfaces must be strictly inert (non-reactive) to the food under the specific conditions of use to prevent chemical contamination, off-flavors, or degradation.

True or False: Machine surfaces should be highly porous to absorb excess moisture and protect food from external contamination.

False. All machine surfaces must be smooth and nonporous, and entirely free from pits and crevices. This specific design physically protects the food from external contamination and prevents the buildup of microbial biofilms.

True or False: Complex food processing machines should be designed to remain fully assembled during sanitation to avoid the risk of reassembly errors.

False. A key design requirement is that machines should be easily dismantled for cleaning to ensure thorough sanitation of all internal components and hard-to-reach areas.

True or False: As long as a detailed manual of operation is available on the production floor, operators do not need formal training on the equipment.

False. While a detailed manual of operation must be available, operators are required to know the process capability of every machine. Furthermore, the operator must be formally trained to operate the equipment as an integrated part of a given process.

It refers to the managerial and non-managerial personnel employed in an organization.

Manpower

True or False: The foundational concept of quality that all personnel must understand is that quality means exceeding customer expectations.

False. Manpower must first understand that quality is strictly defined as conformance to requirements.

True or False: Personnel only need to be trained to execute tasks; empowering them to control unit operations is a strictly managerial duty.

False. Manpower must be both trained and empowered to control unit operations, ensuring the process conforms to prescribed parameters or specifications.

True or False: Supplying the correct equipment is a fundamental requirement for maximizing manpower effectiveness.

True. Every individual in the workforce must have the right tools to properly execute his or her assigned task.

True or False: Recognizing and rewarding personnel is primarily linked to achieving short-term daily quotas rather than long-term organizational goals.

False. Manpower must be recognized and rewarded specifically for their significant contributions to the long-range efforts of the firm.

These are communication tools to define reasonable expectations.

Specifications

These serve as the body of rules for the manufacture and sale of food products.

Specifications

Types of specifications

1. materials

2. processes

3. products

4. methods of test

5. criteria for acceptance or rejection

6. methods of use

These specifications describe and define the product.

Material specifications

These specifications establish the method of quality evaluation and sampling procedures.

Material specifications

These specifications serve to instruct personnel on how to make the product successfully and economically.

Process specifications

These specifications provide the “know-how” to operate each unit operation in conformance to product quality requirements.

Process specifications

These are detailed descriptions of how to measure and evaluate quality characteristics of incoming materials, foods in process, or the quality characteristics of the finished products.

Methods specifications

True or False: Methods specifications can be reliably communicated through verbal agreements among department heads.

False. Methods specifications should be in writing to accurately and consistently convey information to all concerned parties.

These promote the development of international standards and facilitate the exchange of goods and services throughout the world.

ISO Standards

Quality Management and Quality Assurance Standards — Guidelines for Selection and Use

ISO 9000

Quality Systems — Model for Quality Assurance in Design/Development, Production, Installation, and Servicing

ISO 9001

Quality Systems — Model for Quality Assurance in Production and Installation

ISO 9002

Quality Management and Quality Systems Elements — Guidelines

ISO 9004