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Golden Six
CII-Master Class
2nd Dec-2015, New Delhi
Harshad Pathak
Take Home messages the juice…..
Golden Six is
• Common sense (…Caution it is not always common)
• Simple tool to identify the themes /
patterns in food safety
• Preventive measure to drive Continuous
improvement
• Our senses are our tools
• Our wisdom is our skill
• To Fulfil our purpose
Nourishing families so they can flourish
and thrive
Agenda
• What are the “Golden Six”? – A simple way of looking at a plant’s overall food safety conditions
• How does the process work?
– It starts from the outside and moves in
• What are the key indicators?
– Red Flags and Out of Compliance Indicators
• Practical Implementation in factory
• Questions
….a bit of History Why was Golden Six created
• The “Golden Six” was created as a way to simplify the many requirements for a food
manufacturing facility
• The idea was to “boil down” requirements to the very basic expectations for food
plants
• This was done using feedback from
regulatory inspections, internal
inspections and CODEX requirements
• A “Golden Six” assessment can be done relatively quickly to provide an overall
view of a plant’s food safety conditions
What is Golden Six? Let’s keep it simple…
6 Basics of Food Safety to check out, more the Red Tags better Stop……….
Golden Six
Important Tip Are we seeing the same thing?
Get Calibrated, learn to connect the dots…
What should we look for? Devil is in the details…
Key Out of Compliance
Indicators…
Why do we hate
water?
• …Because Pathogens
loves them
• Single most
effective way
to avoid any
microbial
growth in
lines and
environment
• Any external
water coming
inside the
factory is
direct
contamination
of Pathogens
What’s wrong with pests?
• They bring in
Pathogens
• They
contaminate
our products
• Ethnic foods
issue
• Cereals are
prone to
insect
infestation
What does this
tell us?
• They bring in
Pathogens
• They
contaminate
our products
• Ethnic foods
issue
• Cereals are
prone to
insect
infestation
What should we look for? Devil is in the details…
Key Out of Compliance
Indicators…
Why do they
indicate?
• They carry
pathogens
through hands
• They carry
pathogens
through shoes
and materials
• Can
contaminate
with foreign
matter
• Allergen
contamination
What’s wrong with this?
• Foreign
material
contamination
• Microbiologic
al
contamination
• Breeding of
microbes
• Allergen
contamination
What does this
tell us?
• Foreign
material
contamination
• Pest entry
and
contamination
• Breeding of
microbes
• Allergen
contamination
How does that work?
Score Card Helps to determine a pattern
Theme could be a requirement or a specific
area
The Process of Golden Six How we use them in our facilities
Golden Six
How we have implemented…
Must do’s activities visuals… Compliance check to GMP & PPE’s
Daily Must Do’s trending
EHS Must do’s
Q&FS Must do’s
No observation = < 2 observations > 2 observations Days
Safety Goggle
17%
48% 53%
47%
74%
60%
10%
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
Jun Jul Aug Sep Oct Nov Dec
Green Yellow Red
Ear
Plug 100% 100% 100% 100% 100% 100% 100%
0%
20%
40%
60%
80%
100%
120%
Jun Jul Aug Sep Oct Nov Dec
Green Yellow Red
Safety
Shoes
7%
55% 60%
80% 77%
47%
3% 0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
Jun Jul Aug Sep Oct Nov Dec
Green Yellow Red
Hair
net
43%
83%
100% 100% 100% 100% 100%
0%
20%
40%
60%
80%
100%
120%
Jun Jul Aug Sep Oct Nov Dec
Green Yellow Red
No
Jewelry 100% 100% 100% 97% 100% 100% 100%
0%
20%
40%
60%
80%
100%
120%
Jun Jul Aug Sep Oct Nov Dec
Green Yellow Red
No loose object above
waist
Till Date G6 trending The visual monitoring keep action live.
% of Green, Yellow and Red overall days period wise for 2015
G6 trending…… Measurement of every bucket for effective actions
Water control Pest control Sanitation & Housekeeping
Employee practices Overhead cleaning Condition of Bldg / equ
15% 9%
30%
19%
25%39%
46%
27%30%
33%22%
17%
3%
23%
21%19%
8%
19% 18%22%
63%
74%
67%
58%54%
42% 46%
54%52%
44%
0%
10%
20%
30%
40%
50%
60%
70%
80%
P1 P2 P3 P4 P5 P6 P7 P8 P9 P10
59%
57%
42%
65% 54%58%
54%58%
73%
67%
0%4%
6% 8%4% 3%
0% 0%3%
0%
41%
39%
52%
27%
43%
39%
46%42%
24%
33%
0%
10%
20%
30%
40%
50%
60%
70%
80%
P1 P2 P3 P4 P5 P6 P7 P8 P9 P10
7%
0%6%
19%14%
26%
12%15%
12%
22%19% 17%12%
23%
21%
6%
19%
4%9%
22%
74%
83%
82%
58%
64%68%
69%
81% 79%
56%
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
P1 P2 P3 P4 P5 P6 P7 P8 P9 P10
33%
39%
61% 62%57%
52%
62%
54%
39%
56%
11% 13%12%
8%
14% 10%
8%12%
24%22%
56%
48%
27%31%
29%
39%
31%35%
36%
22%
0%
10%
20%
30%
40%
50%
60%
70%
P1 P2 P3 P4 P5 P6 P7 P8 P9 P10
74%
65% 73%81%
96%
90%
77%
85%
76% 78%
15%
0% 0%
12%
0%
6%19%
8% 9% 11%11%
35%
27%
8%
4%3% 4%
8%
15%11%
0%
20%
40%
60%
80%
100%
120%
P1 P2 P3 P4 P5 P6 P7 P8 P9 P10
7%
39%
42%23%
39%
58%62%
65%
58%
44%
7% 9%
0%
15%7% 6%
0% 0%3%
11%
85%
52%
58% 62%
54%
35%38%
35%39%
44%
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
P1 P2 P3 P4 P5 P6 P7 P8 P9 P10
Period P10 Period P10 Period P10
STATUS (All) STATUS closed STATUS (Multiple Items)
Row Labels Count of Nature of finding Row Labels Count of Nature of finding Row Labels Count of Nature of finding
Condition of bldg /equip 86 Condition of bldg /equip 42 Condition of bldg /equip 44
GMP practices 60 GMP practices 37 GMP practices 23
Overhead food stream 16 Overhead food stream 8 Overhead food stream 8
Pest Control 6 Pest Control 5 Pest Control 1
Sanitation / Housekeeping 29 Sanitation / Housekeeping 22 Sanitation / Housekeeping 7
water control 12 water control 8 water control 4
Grand Total 209 Grand Total 122 Grand Total 87
Period P10 Period P10 Period P10
STATUS (All) STATUS closed STATUS Pending
Row Labels Count of Nature of finding Row Labels Count of Nature of finding Row Labels Count of Nature of finding
Ashok M 97 Ashok M 54 Ashok M 43
Nilesh A 9 Nilesh A 6 Nilesh A 3
Rupesh 7 Rupesh 7 Sangram 1
Sangram 1 Shyam 1 Shyam 3
Shyam 4 Rajesh K 11 (blank) 2
(blank) 2 Sandeep R. 1 Rajesh K 4
Rajesh K 15 Prashant K 1 Nitin N 1
Sandeep R. 1 Vijay G 7 Prashant K 5
Nitin N 1 Manish J. 1 Rupesh 1
Prashant K 6 Sandeep R 6 Manish J. 1
Vijay G 7 pramod w 6 Sandeep R 2
Rupesh 1 Rupesh s 3 Shilpika J 5
Manish J. 2 Rajesh/Vijay 4 pramod w 7
Sandeep R 8 Hemant 1 Rajesh k. 1
Shilpika J 5 Rajesh K/Vijay G 1 Rupesh s 1
pramod w 13 Rajesh 1 Rajesh/Vijay 1
Rajesh k. 1 Rupesh/Santosh 1 Jitendra K 1
Rupesh s 4 Sonavane B. 1 Amit/Rajesh K/Vijay G 1
Rajesh/Vijay 5 Rajes K 1 Rajes K 1
Jitendra K 1 Rajesh v 2 Bharat S 2
Amit/Rajesh K/Vijay G 1 Rupesh S/Santosh 3 Hemant S 1
Hemant 1 Santosh & Rajesh K 1 Grand Total 87
Rajesh K/Vijay G 1 Sandeep R & Santosh G 2
Rajesh 1 Grand Total 122
Rupesh/Santosh 1
Sonavane B. 1
Rajes K 2
Rajesh v 2
Rupesh S/Santosh 3
Bharat S 2
Santosh & Rajesh K 1
Sandeep R & Santosh G 2
Hemant S 1
Grand Total 209
G6 findings & Action Tracker Every action & accountability tracked..
58 % closure of the
points
G6 Visual Trend Visual trend to target specific area…
Finally it is Culture…… Do you know where are you on this maturity journey…
Golden Six Helps
Here
Questions?
Thank You for your attention
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