Unit of Competency Mapping – Information for Teachers/Assessors – Information for Learners

FDFFST4041A Mapping and Delivery Guide
Identify and implement product safety and quality for cooked poultry product manufacturing

Version 1.0
Issue Date: May 2024


Qualification -
Unit of Competency FDFFST4041A - Identify and implement product safety and quality for cooked poultry product manufacturing
Description This unit covers the skills and knowledge required to review the quality, safety and operational procedures to manufacture cooked poultry products
Employability Skills This unit contains employability skills.
Learning Outcomes and Application This unit applies to food science and technology personnel who have roles in product design, quality assurance and production management. The unit typically applies to staff who have responsibility for maintaining product safety, quality and efficiency in cooked poultry products. This unit includes using knowledge of food science and processes to determine the required food safety, quality and performance required from food production equipment. Depending on the workplace application, liaison may be required with engineering and maintenance specialists.
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.
Prerequisites/co-requisites Not applicable.
Competency Field
Development and validation strategy and guide for assessors and learners Student Learning Resources Handouts
Activities 		Slides
PPT 		Assessment 1 Assessment 2 Assessment 3 Assessment 4
Elements of Competency Performance Criteria              
Element: Check the cooked poultry product preparation and processing areas and equipment
  • Procedures for pre-operational equipment checks are checked for accordance with workplace policies and procedures, and manufacturer’s instructions
  • Regulatory requirements and safe work practices and safety equipment are implemented
  • Pre-operational checks and procedures are conducted or supervised and
  • Risk of contamination or variations in product quality are reported in accordance with workplace policies and procedures
  • Regulatory requirements for the operation are monitored
  • Physical hazards which may affect cooked poultry products are recorded
  • Optimum methods for physical hazard risk reduction are implemented
       
Element: Monitor the preparation of ingredients, and processing equipment and areas
  • Ingredients are sourced by type, quality and safety criteria, according to product specifications
  • Types of chicken meat, by-product, stock, additive, binder and spices are sourced according to the formulation specifications and regulatory requirements
  • Handling requirements for ingredients to prevent contamination and to ensure customer and production requirements, quality and safety are monitored
  • Processing equipment is monitored and operating procedures explained to operators according to manufacturer’s and workplace specifications
  • Relevant processing area hygiene and sanitation requirements are monitored as specified in workplace procedures and regulatory requirements
  • Production system and equipment for the preparation and manufacture of cooked poultry products are monitored
  • Procedures for pre-operational equipment checks are applied in accordance with workplace policies and procedures, and manufacturer’s instructions
  • Cleaning regime is monitored to ensure hygiene and safe work area requirements are maintained
       
Element: Monitor the production of cooked poultry and further processed products
  • Relevant time, temperature and humidity requirements for cooking and packaging are monitored in accordance with product specifications, regulatory requirements and enterprise guidelines
  • Relevant consistency, appearance, texture and monitoring requirements are monitored in accordance with product specifications and regulatory requirements
  • Product sampling and testing and sensory analysis regime is monitored to ensure conformance with regulatory and enterprise requirements
  • Procedures for rejection, reprocessing and/or recall for products which do not meet specifications or hygiene and sanitation requirements are implemented and reviewed against regulatory requirements and industry guidelines
  • Relevant processing area hygiene and sanitation requirements are monitored as specified in workplace procedures and regulatory requirements
       
Element: Overview the implementation of the HACCP plan for the production of cooked poultry products
  • Critical control points (CCPs) and control points for prevention and control of bacterial contamination (e.g. process controls and systems) are implemented
  • Control methods to prevent microbiological contamination are explained to workers and implemented
  • Monitoring processes are implemented for critical limits for CCPs
  • Validation requirements for critical limits of HACCP programs are carried out
  • Documented procedures are implemented which ensure any CCPs which are out of control are brought back into control and affected product is suitably handled
  • Documented procedures are implemented to ensure the whole HACCP system is regularly audited and verified as working effectively
  • All documents and records required for the system are kept available, up-to-date and in use
       
Element: Review production processes
  • Product sampling and testing and sensory analysis are conducted and analysed
  • Product formulations and operating procedures are reviewed
  • Safe work systems for processing of cooked poultry products are reviewed
  • Environmental impacts and energy efficiencies are reviewed for processing of cooked poultry products
       


Evidence Required

List the assessment methods to be used and the context and resources required for assessment. Copy and paste the relevant sections from the evidence guide below and then re-write these in plain English.

The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, range statement and the Assessment Guidelines for the Training Package.

Overview of assessment

A person who demonstrates competency in this unit must be able to review the manufacturing processes for cooked poultry product in terms of processing efficiency, quality of product, food safety, workplace safety and environmental impact.

Critical aspects for assessment and evidence required to demonstrate competency in this unit

Critical aspects of assessment must include evidence of the ability to supervise cooked poultry manufacturing processes including: reviewing the CCPs and critical limits in the food safety plan for cooked poultry products; monitoring commercial processing techniques to produce cooked poultry products; diagnosing and reporting problems for manufacturing of cooked poultry products; carrying out sensory evaluation and product testing; and reviewing the production system for food safety and quality and environmental impact

Context of and specific resources for assessment

Assessment of performance requirements in this unit should be undertaken within the context of food technology. Competency is demonstrated by performance of all stated criteria, including the critical aspects and knowledge and skills elaborated in the Evidence Guide, and within the scope as defined by the Range Statements applicable to the workplace environment.

Assessment must occur in a real or simulated workplace where the assessee has access to:

Production process and related equipment, manufacturers’ advice and operating procedures

Methods and related software systems as required for collecting data, analysing data and compiling into a report

Laboratory facilities or reports to assess food microbiology and chemistry

Method of assessment

The following assessment methods are suggested:

Analysis of product and process under the candidate’s supervision

Report on a review of a manufacturing process for cooked poultry products

Observation of candidate collecting and analysing data

Written and/or oral questioning to assess knowledge and understanding

Completing workplace documentation

Third party reports from experienced practitioner

Field Reports

Guidance information for assessment

Evidence should be gathered over a period of time in a range of actual or simulated environments.

Submission Requirements

List each assessment task's title, type (eg project, observation/demonstration, essay, assignment, checklist) and due date here

Assessment task 1: [title]      Due date:

(add new lines for each of the assessment tasks)

Assessment Tasks

Copy and paste from the following data to produce each assessment task. Write these in plain English and spell out how, when and where the task is to be carried out, under what conditions, and what resources are needed. Include guidelines about how well the candidate has to perform a task for it to be judged satisfactory.

Required skills include:

Ability to:

monitor production of cooked poultry products

apply procedures to ensure the product is fit for human consumption and meets regulatory, food safety and quality requirements

overview the implementation of the HACCP plan for the production of cooked poultry products

carry out product sampling and testing according to the HACCP plan and operational procedures

provide relevant information to work colleagues to facilitate understanding of, and compliance with, the Australian Standards and associated regulations

take action to improve own work practice as a result of self-evaluation, feedback from others, or changed work practices, regulations or technology

use technology to access information, prepare reports, and to access and prepare relevant data

implement workplace OH&S procedures.

Required knowledge includes:

Knowledge of:

the steps in the cooking of poultry

the range of types of chilled cooked poultry products and their processing stages

types of micro-organisms and bacteria causing food poisoning

food poisoning and food spoilage (shelf life) effects of bacterial contamination

sources of bacterial contamination for both ‘ready to heat’ and ‘ready to eat’ chicken products

microbial hazards for ‘par cooked’ further processed poultry products

growth characteristics and requirements of relevant bacteria species

microbiological criteria in cooked poultry products production and microbiological limits, particularly the following significant microbial pathogens: enterohaemorrhagic Escherichiacoli, Salmonella, enterotoxin of Staphylococcus aureus and Listeria monocytogenes

chemical hazards which may affect cooked poultry products

effects or impact of physical hazards on cooked poultry products

procedures for raw materials storage, handling and preparation

safe food handling procedures

the impact of the raw material on product quality and food safety

physical food safety hazards

safe work procedures

sanitation and hygiene procedures

HACCP principles and critical limits in a HACCP program for cooked poultry products

identification of CCPs and critical limits

water and energy use and recycling in processing

packaging technologies and procedures

sensory analysis

food sampling and testing

storage requirements for processed product

regulatory requirements associated with the production of cooked poultry products

environmental impacts of the food processing operation.

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.

Legislation

Legislative requirements are typically reflected in procedures and specifications. Legislation relevant to this industry includes the Food Standards Code including labeling, weights and measures legislation; and legislation covering food safety, environmental management, occupational health and safety, anti-discrimination and equal opportunity.

Policies and procedures

Work is carried out according to company procedures, regulatory and licensing requirements, legislative requirements, and industrial awards and agreements.

Safe work procedures

Examples of specific task related procedures may include:

handling of chemicals

use of PPE

Physical hazards

These include any hard objects that can contaminate product including metal shavings, packaging, clothing or jewellery. Physical hazards also include safety hazards for operators and other staff such as steam, hot surfaces, working with fats and oils, noise, operating equipment and manual handling.

Cooked poultry products

These may be sold as ‘ready to heat’, ‘ready to eat’, and par cooked products. The products may include bone-in/ bone-out natural portions, formed products or filled products.

Retailing systems for poultry product

These may include retail, food service and quick service restaurants (QSRs).

Ingredients

May include sauces and fillings, spices, herbs, fruit or vegetables, water, milk product, noodles, pasta, nuts, mushrooms or breads

Micro-organisms

bacteria

mould

virus

yeast.

Workplace requirements

enterprise-specific requirements

OH&S requirements

Quality Assurance requirements

Standard Operating Procedures

the ability to perform the task to production requirements

work instructions.

OH&S

Enterprise OH&S policies, procedures and programs

OH&S legal requirements

Personal Protective equipment (PPE) which may include:

coat and apron

ear plugs or muffs

eye and facial protection

head-wear

lifting assistance

mesh apron

protective boot covers

protective hand and arm covering

protective head and hair covering

uniforms

waterproof clothing

work, safety or waterproof footwear

requirements set out in standards, codes of practice etc.

Copy and paste from the following performance criteria to create an observation checklist for each task. When you have finished writing your assessment tool every one of these must have been addressed, preferably several times in a variety of contexts. To ensure this occurs download the assessment matrix for the unit; enter each assessment task as a column header and place check marks against each performance criteria that task addresses.

Observation Checklist

Tasks to be observed according to workplace/college/TAFE policy and procedures, relevant legislation and Codes of Practice Yes No Comments/feedback
Procedures for pre-operational equipment checks are checked for accordance with workplace policies and procedures, and manufacturer’s instructions 
Regulatory requirements and safe work practices and safety equipment are implemented 
Pre-operational checks and procedures are conducted or supervised and 
Risk of contamination or variations in product quality are reported in accordance with workplace policies and procedures 
Regulatory requirements for the operation are monitored 
Physical hazards which may affect cooked poultry products are recorded 
Optimum methods for physical hazard risk reduction are implemented 
Ingredients are sourced by type, quality and safety criteria, according to product specifications 
Types of chicken meat, by-product, stock, additive, binder and spices are sourced according to the formulation specifications and regulatory requirements 
Handling requirements for ingredients to prevent contamination and to ensure customer and production requirements, quality and safety are monitored 
Processing equipment is monitored and operating procedures explained to operators according to manufacturer’s and workplace specifications 
Relevant processing area hygiene and sanitation requirements are monitored as specified in workplace procedures and regulatory requirements 
Production system and equipment for the preparation and manufacture of cooked poultry products are monitored 
Procedures for pre-operational equipment checks are applied in accordance with workplace policies and procedures, and manufacturer’s instructions 
Cleaning regime is monitored to ensure hygiene and safe work area requirements are maintained 
Relevant time, temperature and humidity requirements for cooking and packaging are monitored in accordance with product specifications, regulatory requirements and enterprise guidelines 
Relevant consistency, appearance, texture and monitoring requirements are monitored in accordance with product specifications and regulatory requirements 
Product sampling and testing and sensory analysis regime is monitored to ensure conformance with regulatory and enterprise requirements 
Procedures for rejection, reprocessing and/or recall for products which do not meet specifications or hygiene and sanitation requirements are implemented and reviewed against regulatory requirements and industry guidelines 
Relevant processing area hygiene and sanitation requirements are monitored as specified in workplace procedures and regulatory requirements 
Critical control points (CCPs) and control points for prevention and control of bacterial contamination (e.g. process controls and systems) are implemented 
Control methods to prevent microbiological contamination are explained to workers and implemented 
Monitoring processes are implemented for critical limits for CCPs 
Validation requirements for critical limits of HACCP programs are carried out 
Documented procedures are implemented which ensure any CCPs which are out of control are brought back into control and affected product is suitably handled 
Documented procedures are implemented to ensure the whole HACCP system is regularly audited and verified as working effectively 
All documents and records required for the system are kept available, up-to-date and in use 
Product sampling and testing and sensory analysis are conducted and analysed 
Product formulations and operating procedures are reviewed 
Safe work systems for processing of cooked poultry products are reviewed 
Environmental impacts and energy efficiencies are reviewed for processing of cooked poultry products 

Forms

Assessment Cover Sheet

FDFFST4041A - Identify and implement product safety and quality for cooked poultry product manufacturing
Assessment task 1: [title]

Student name:

Student ID:

I declare that the assessment tasks submitted for this unit are my own work.

Student signature:

Result: Competent Not yet competent

Feedback to student

 

 

 

 

 

 

 

 

Assessor name:

Signature:

Date:

Assessment Record Sheet

FDFFST4041A - Identify and implement product safety and quality for cooked poultry product manufacturing

Student name:

Student ID:

Assessment task 1: [title] Result: Competent Not yet competent

(add lines for each task)

Feedback to student:

 

 

 

 

 

 

 

 

Overall assessment result: Competent Not yet competent

Assessor name:

Signature:

Date:

Student signature:

Date: