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

FDFFST5030A Mapping and Delivery Guide
Develop, manage and maintain quality systems for food processing

Version 1.0
Issue Date: May 2024


Qualification -
Unit of Competency FDFFST5030A - Develop, manage and maintain quality systems for food processing
Description This unit covers the skills and knowledge required to develop, manage and maintain quality systems for food processing. It also covers the skills and knowledge needed to lead people, manage systems and build quality into all enterprise systems and operations. The development and management of quality systems affects the ability of the enterprise to operate in specific markets and influences customer and consumer confidence in enterprise products.
Employability Skills This unit contains employability skills.
Learning Outcomes and Application This unit applies to Quality Assurance (QA) managers and personnel, production managers and supervisors operating in a food processing context. At this level individuals exercise considerable responsibility and accountability within enterprise structures and are required to make primary contributions to the values, goals and operations of the enterprise. They will typically have responsibility for the establishment and review of systems for the site or department. They may work with the assistance of external experts to develop plans and strategies.
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: Establish requirements of the quality system
  • Policies expressing the organisation’s commitment to the quality system and processes are developed.
  • Legislative requirements for enterprise quality systems are identified.
  • Scope and objectives of the quality system are determined, including links with all enterprise operations, customers, suppliers and contractors.
  • Quality performance standards, including customer and supplier service standards, are established consistent with the direction and goals of the enterprise.
  • Resource requirements are identified and included in financial, human resource and operational plans.
       
Element: Design and prepare for the quality system
  • Quality systems are selected and designed to meet enterprise, customer and regulatory requirements.
  • Quality principles are applied to all enterprise operations to achieve business goals and performance standards.
  • Responsibilities for development, implementation and operation of the system are clearly defined and communicated.
  • Personnel from all levels and areas of the organisation are involved in the development and implementation of the quality system.
  • System components, procedures and supporting documentation are developed and validated.
  • Consultative and communication strategies are developed to link the quality system with all aspects of enterprise operations.
  • Supplier or contractor service standards and audit requirements are determined and negotiated.
  • The quality system is designed and prepared for
  • Performance measures and indicators are developed to measure performance against policies, goals and performance standards.
       
Element: Implement and monitor the quality system
  • Implementation plan is prepared and resourced.
  • Training plans to provide personnel at all levels with quality concepts and skills are prepared and resourced.
  • Quality system requirements and customer focus are addressed in the establishment, operation and evaluation of all enterprise systems.
  • Control and preventative action measures are identified and validated.
  • Corrective action procedures are developed and monitored.
  • Procedures for reporting, recording and responding to non-conformances and non-compliances are established.
  • Customer and supplier service standards are monitored and documented.
  • Quality data is collected and analysed, and implications reported.
  • Quality costs and performance are monitored.
  • Quality system is prepared for external review and approval by relevant authorities.
       
Element: Continuously improve the quality system
  • Impacts of the quality system on enterprise operations are monitored and reviewed.
  • Responses to customer complaints and requests are resolved and used to improve the system.
  • Procedures for the ongoing identification and resolution of issues are established.
  • Quality system is updated for changes in process, technical information, customer and regulatory requirements.
  • Stakeholders are included in decision making and continuous improvement processes and strategies.
  • Quality results, findings and conclusions are fed into improvement processes.
  • Costs and benefits of the quality system are analysed.
  • Quality goals and targets are continuously reviewed.
       
Element: Communicate quality outcomes
  • Certification of product and processes consistent with quality outcomes is completed according to customer and regulatory requirements.
  • Regulatory authorities and agencies are promptly notified of breaches and non-compliance incidents.
  • Quality outcomes are used to promote public confidence in enterprise products and services.
       


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 develop, manage and maintain quality systems for food processing.

Evidence is also required in the ability to lead people, manage systems and build quality into all enterprise systems and operations.

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

Competency must be demonstrated in the ability to perform consistently at the required standard. In particular, assessors should look to see evidence of the ability to: develop and document quality system procedures to enterprise and legislative requirements; to implement the quality systems in a typical food production process including establishing responsibilities, training requirements and reporting arrangements; to collect and analyse process control data and other data and recommend quality system improvements; and to develop procedures to deal with non-conformance in relation to quality system requirements.

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

A food processing enterprise with documentation to support the implementation of a QA system

Methods and related software systems as required for collecting data and calculating yields, efficiencies and material variances appropriate to production environment

Tests used to report relevant product/process information and recorded results

Method of assessment

The following assessment methods are suggested:

Observation of candidate carrying out product development and conducting a range of tests and procedures

Written and/or oral questioning to assess knowledge and understanding

Completing workplace documentation

Third party reports from experienced practitioner

Case studies

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

Ability to:

analyse complex statistical data and prepare corrective responses to non-conformances and variations identified in the data, relevant to enterprise quality systems and operations.

apply quality concepts and tools to problem-solving and the development of quality data collection, data management systems and analysis strategies.

apply substantial product and process knowledge to the development of the quality system and the interpretation of quality data.

communicate quality goals, requirements and findings to stakeholders in formats and styles appropriate to the context and purpose.

consult, negotiate with and report to regulatory authorities openly and promptly, consistent with enterprise ethical standards. This includes the notification of breaches and the preparation of non-compliance reports.

develop consultative and feedback procedures and opportunities for identification and resolution of quality issues and problems.

develop continuous improvement processes and team building using the ‘plan, do, check, act’ cycle.

develop quality policies for the enterprise in consultation with senior management and other stakeholders.

develop workforce commitment, capability and responsibility for the quality system. This involves identifying, negotiating and scheduling training, inclusion of responsibilities and duties relating to quality system implementation and integration in all job descriptions and work instructions, clear communication of responsibilities and requirements, delegation of tasks and responsibilities and inclusion of the workforce in consultative and continuous improvement processes.

ensure the quality system meets legislative and regulatory requirements.

exercise judgement, pragmatism and quality knowledge in the management and resolution of quality issues and problems.

identify and apply relevant OH&S and workplace requirements.

identify and describe process capability.

identify appropriate monitoring systems and strategies to support the enterprise quality system.

identify the applicable quality standards, regulations, codes, and legislation and customer requirements for the quality system and explain the implications for the enterprise.

identify research and update sources of quality information and advice including technical and regulatory information to support enterprise quality system.

lead personnel (e.g. Hazard Analysis Critical Control Point (HACCP) team, management, quality team, meat inspection team, laboratory, maintenance teams, processors and operators) in the implementation and improvement of the quality system.

monitor and analyse the costs of the quality system, including prevention costs, appraisal costs, total quality costs and failure costs.

monitor and certify processes and product to meet third party requirements (eg importing country, public health requirements, customers).

oversee audit processes (internal and external), act on audit findings and provide feedback to personnel for improvement of the system.

oversee the preparation for third party certification (where appropriate).

plan and resource the enterprise training strategy, consistent with regulatory requirements to assist personnel at all levels in the implementation of the quality system.

prepare and sign off quality policies, manuals and documentation for the enterprise, including the preparation and updating of preventative, corrective and responsive procedures and strategies, supplier criteria and specifications, supplier and contractor audit requirements.

prepare quality implementation plans, identifying goals, key personnel and areas, resources, strategies, timelines and milestones.

present reports according to legal and enterprise requirements.

resolve customer complaints promptly and provide corrective action responses.

use appropriate questioning, observation, listening and recording skills in the collection and monitoring of quality data.

where quality systems are based on HACCP principles or good manufacturing practice, explain these principles and the implications for the enterprise quality system.

apply relevant communication and mathematical skills.

Required knowledge

Knowledge of:

the key concepts, philosophies and tools of quality management.

the management and organisational structure of the enterprise and its impact on enterprise systems.

the role audits play in a quality system.

documentation requirements of the quality system (including levels) and their roles in the functioning of the system, including the requirement for effective and secure quality record-keeping systems.

enterprise goals and directions and their implications for the quality system.

the legal requirements for the establishment and maintenance of the enterprise QA system including responsibilities for reporting breaches to authorities and implementing audit findings.

the principles and functions of hazard analysis and control, validation (including auditing) and verification in quality systems.

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.

Quality systems

These may include

Australian and New Zealand Food Standards

Food and meat industry sector specific standards

International standards e.g. ISO 9000 series

Personal Qualities Assessment (PQA)

Enterprise specific requirements

Requirements of the quality system

These may include

Codes of practice, regulations, Safety Data Sheets (SDSs)

control of documents, data, quality records

coverage of contracts, purchasing, supply, processing,

handling, storage, processing, packaging, preservation, storage and delivery of food products

definition of management responsibilities

design and process controls

inspecting and testing, control of non-conforming

product, preventative and corrective action, auditing

management of links and impacts on all systems within the enterprise

production identification and traceability

training.

Systems components and procedures

These may include

correction e.g. disposition, corrective action, liability management, customer complaint resolution

prevention e.g. training, operator feedback, manuals, technology and equipment reliability and maintenance, statistical collection and information, supplier QA, Standard Operating Procedures (SOPs) and work instructions

Statistical data analysis

This may include

correlation and regression analysis, bi-variate and multivariate analysis

distribution theory

estimating and hypothesis testing

probability and statistical inference

process stability, capability and management

reliability planning

sampling

statistical process control requirements, charting applications

variations and variation monitoring.

Quality tools

These may include cause and effect and fish bone diagrams, control charts, data points, flow charts, histograms, prioritisation matrices, process improvement models, process capability, pareto charts and team structures.

Data management systems

These may be manual or computerised and cover data collection, data monitoring and data analysis and interpretation.

Data analysis and interpretation

This may include

Acceptable Quality Level (AQLs)

Chemical Lean (CL) levels

microbiological analysis, eg Total Viable Counts (TVC), e-coli counts

process capability analysis

process variation analysis

product monitoring

statistical process control

temperature eg cooling and chilling rates.

Documentation for the QA process for food safety

This may include

amendment registers

Critical Control Points (CCPs) monitoring forms and additional monitoring requirements and supporting programs

CCP work instructions

HACCP audit table

HACCP team register, product description and use

process flow charts, factory floor plan, hazard analysis table

schedules relating to hygiene, cleaning and sanitation

procedures, work instructions, approved chemicals,

calibration, pest control, training, product identification and recall.

Legislation

Australian and international standards

Acts of Federal and State Parliament

State and territories’ food regulations

International, Australian and State environmental protocols and regulations regarding effluent.

OHS requirements

Codes of practice, regulations, safety data sheets (SDSs)

Enterprise and process specific OHS requirements

Regulatory requirements

These may include

animal welfare

commercial law including fair trading, trade practices

consumer law

corporate law, including registration, licensing, financial

reporting

environmental and waste management

equal opportunity, anti-discrimination and sexual harassment

Legislation

hygiene and sanitation requirements

industrial awards, agreements

relevant regulations

state regulations regarding food processing

taxation.

Process capability

This includes

operational capability (resources, risks, opportunities, commitments)

technical capability (personnel, equipment, systems, suppliers).

Monitoring systems and

strategies

These may include

audits and reviews

feedback from stakeholders

inspection and testing procedures and regimes (including chemical and microbiological testing procedures) for validation and verification

statistical collection and analysis.

Third party certification

This includes

regulatory agencies

accountabilities, inspection stamps/seals

customer requirements and specifications

importing country requirements

licensing or registration requirements

national or international quality endorsement

product description and certification.

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
Policies expressing the organisation’s commitment to the quality system and processes are developed. 
Legislative requirements for enterprise quality systems are identified. 
Scope and objectives of the quality system are determined, including links with all enterprise operations, customers, suppliers and contractors. 
Quality performance standards, including customer and supplier service standards, are established consistent with the direction and goals of the enterprise. 
Resource requirements are identified and included in financial, human resource and operational plans. 
Quality systems are selected and designed to meet enterprise, customer and regulatory requirements. 
Quality principles are applied to all enterprise operations to achieve business goals and performance standards. 
Responsibilities for development, implementation and operation of the system are clearly defined and communicated. 
Personnel from all levels and areas of the organisation are involved in the development and implementation of the quality system. 
System components, procedures and supporting documentation are developed and validated. 
Consultative and communication strategies are developed to link the quality system with all aspects of enterprise operations. 
Supplier or contractor service standards and audit requirements are determined and negotiated. 
The quality system is designed and prepared for 
Performance measures and indicators are developed to measure performance against policies, goals and performance standards. 
Implementation plan is prepared and resourced. 
Training plans to provide personnel at all levels with quality concepts and skills are prepared and resourced. 
Quality system requirements and customer focus are addressed in the establishment, operation and evaluation of all enterprise systems. 
Control and preventative action measures are identified and validated. 
Corrective action procedures are developed and monitored. 
Procedures for reporting, recording and responding to non-conformances and non-compliances are established. 
Customer and supplier service standards are monitored and documented. 
Quality data is collected and analysed, and implications reported. 
Quality costs and performance are monitored. 
Quality system is prepared for external review and approval by relevant authorities. 
Impacts of the quality system on enterprise operations are monitored and reviewed. 
Responses to customer complaints and requests are resolved and used to improve the system. 
Procedures for the ongoing identification and resolution of issues are established. 
Quality system is updated for changes in process, technical information, customer and regulatory requirements. 
Stakeholders are included in decision making and continuous improvement processes and strategies. 
Quality results, findings and conclusions are fed into improvement processes. 
Costs and benefits of the quality system are analysed. 
Quality goals and targets are continuously reviewed. 
Certification of product and processes consistent with quality outcomes is completed according to customer and regulatory requirements. 
Regulatory authorities and agencies are promptly notified of breaches and non-compliance incidents. 
Quality outcomes are used to promote public confidence in enterprise products and services. 

Forms

Assessment Cover Sheet

FDFFST5030A - Develop, manage and maintain quality systems for food processing
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