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Case study: IFM for a consumer foods client

Here is an exclusive look into OneSIS’s datasheet, SOPs and innovations for a leading food processing client, where it provides housekeeping, security, production support staffing and other services.

Locations:   Nanjangud, Mysore, Goa and Sanand

Total area serviced:   1 million square feet

Products manufactured:   Noodles/Coffee/Chocolates

Manpower:   300+

Serving for:   5 years

Areas to be serviced

Utility areas, mixing room, chocolate production areas, starter rooms, cold storage, product solution center, packing, batching and storing,

Designing SOPs
  • Undertake a time-motion study for cleaning activities in each area, mapping man hours to cleaning. Identify suitable cleaning equipment/tools and tackles for each plant area
  • Cleaning chemicals chosen based on the food item produced in the plant – normally green chemicals.
  • Mapping the production activity from raw material intake to despatch of finished goods, and designing the SOP to map each production-flow process
Control of operations
  • Incoming material procured as per internally laid down specification & from an approved vendor.
  • Raw material is inspected at the time of receiving for food safety hazards.
  • Incoming material, semi-final or final products are stored according to their temperature and humidity requirements, in a hygienic environment. FIFO & FEFO is practised.
  • Requisite time and temperature is achieved, maintained, monitored and recorded.
  • Food manufactured/processed is packed in a hygienic manner.
  • Packaging materials are food grade & in sound condition.
  • Cleaning chemicals and other hazardous substances are clearly identified and stored separately from food.
  • Transporting vehicles for food use are kept clean and maintained in good repair. They are capable of meeting requisite temperatures (where applicable).
Maintenance & sanitisation
  • Cleaning of manufacturing equipment and food premises is done as per cleaning schedule & cleaning program.
  • Preventive maintenance of equipment and machinery is carried out regularly as per the instructions of the manufacturer.
  • Measuring & monitoring devices are calibrated periodically.
  • Pest control activities are carried out by trained and experienced personnel.
  • Drains are designed to meet expected flow loads and equipped with traps to capture contaminants.
  • Food waste and other refuse are removed periodically from food handling areas to avoid accumulation.
  • Disposal of sewage and effluents is done in conformity with standards laid down under Environment Protection Act, 1986.
Innovations introduced
  • Implementing Smart Surface Disinfection Program for the Production Areas/QA Labs, which prevents cross contamination and is very effective for infection control.
  • Use Airborne Infection Control to improve the Indoor Air Quality, especially in the QA labs and Production Areas.
  • Implementing UV Air Sanitizers, harnessing the power of UV-C rays to alter the DNA of harmful microorganisms.
  • Use of robotics cleaning and scrubbing machines to minimise human intervention and thereby cross contamination.
  • Implemented Smart Cleaning Program, replacing traditional method of cleaning with customized Smart Clean housekeeping trolleys, pre wet cleaning system, microfibre mops and dusters.
  • Implementation of E-checklists replacing manual checklists
  • Digitised Asset Management to track equipment and working condition to ensure no downtime for cleaning due to unavailability of equipment.

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