M&M FOOD INDUSTRIES

Quality Control System

Complete Deep Analysis Guide

IPC Report | Filling Report | Checklist | NCR System

Product: FCOJ (Frozen Concentrated Orange Juice)

Batch Reference: 290426/OC | Date: 29.04.2026

For Quality Engineers & Production Supervisors

TABLE OF CONTENTS

1 Overview: What is In-Process Quality Control? 3

2 IPC Report — Complete Deep Analysis 4

2.1 What is IPC and Why Does It Exist? 4

2.2 The Time-Hour Grid Explained 4

2.3 Every Row: Step-by-Step Deep Dive 5

2.4 Reading the Actual Data from Your Report 8

2.5 CCP Points — The Critical Safety Gates 9

3 Filling Report — Complete Deep Analysis 10

3.1 Purpose & Legal Importance 10

3.2 Every Column Explained 10

3.3 Weight Tolerances & Why They Matter 11

4 Checklist Report — Structure & Importance 12

5 How to Write an NCR (Non-Conformance Report) 13

5.1 What Triggers an NCR? 13

5.2 NCR Template & Every Field Explained 14

5.3 NCR Examples from Your Actual Data 15

6 How to Judge: Is Production Running Correctly? 16

7 Decision Flow: What To Do When Something Goes Wrong 17

8 Quick Reference Card 18

 1 SECTION 1 — OVERVIEW: WHAT IS IN-PROCESS
QUALITY CONTROL?

The Big Picture

Quality control in food manufacturing is not just about testing the final product. By the time a product is
finished, it's too late to fix problems — you have already wasted raw materials, time, labor, and energy. The
entire purpose of In-Process Control is to catch problems WHILE they are happening, at each step of the
process, so you can correct them immediately before they propagate further.

Think of it like driving a car: you don't wait until you crash to check your steering. You constantly watch the
road, check mirrors, and correct small deviations before they become accidents. The IPC Report is your
'dashboard' for the production line.

REPORT TYPE ANSWERS THE QUESTION TIMING WHO FILLS IT

IPC Report Is the PROCESS running correctly right now?Every hour, during production Quality Engineer

Filling Report What PRODUCT did we actually fill and when? Every filling operation Quality Engineer

Checklist Is the LINE clean and ready? Before start / after shutdown Quality Engineer

NCR Something went WRONG — what do we do? When deviation detectedQuality Engineer + Supervisor
 2 SECTION 2 — IPC REPORT: COMPLETE DEEP
ANALYSIS

2.1 — What is the IPC Report and Why Does It Exist?

IPC stands for In-Process Control. It is a structured hourly monitoring form that requires a trained quality
engineer to physically walk the production line, take measurements, make visual checks, and record findings
at defined time intervals. The report is a legal and quality record — it proves due diligence.

Your specific IPC report covers the FCOJ (Frozen Concentrated Orange Juice) line at M&M Food Industries.
The batch number 290426/OC was produced on 29.04.2026. The checks started around 13:00 and
production encountered issues by 14:41.

KEY INSIGHT: Why Record Every Hour?

Food safety standards (ISO 22000, HACCP, BRC, IFS) require documented evidence that Critical Control
Points (CCPs) were monitored continuously. If a batch is ever questioned — by a customer, regulator, or
during an audit — this hourly record is your legal defense. Missing a time slot is not just a quality gap; it is
a compliance failure.

2.2 — The Time-Hour Grid Explained

The top of the IPC report shows a timeline from 8:00 AM through 7:00 AM (next day), representing a full
23-hour production window for 24/7 operations. Each COLUMN represents one hour checkpoint. Each ROW
represents one quality parameter being checked.

The engineer fills in the cell at the intersection of the time and the parameter. A checkmark (✓) means
'passed visual inspection'. A number means 'measured value'. An empty cell means 'not checked yet' OR
'production not running at this hour'.

2.3 — Every Parameter: Deep Technical Analysis

WHAT HAPPENS IF
# PARAMETER STANDARD WHAT IT MEANS WHY IT MATTERS VIOLATED

1 Basin Fruite Clean The large water basin where First contact point for fruit. Microbial contamination of all
(Fruit Basin) incoming oranges are first received Any contamination here fruit. Cross-contamination
and washed. Engineer visually enters the entire process. between batches. Potential
checks for debris, old fruit, dirty Also affects washing for mold spores in final
water, mold buildup. efficiency. product. Issue NCR + STOP
LINE + Clean.
2 Sorter N.O. NLT 3 (Not Number of workers actively sorting Sorting is the only mechanical Defective fruit passes to
Less Than 3 fruit on the sorting conveyor. defense against defective fruit processing. Brix values drop.
workers) Engineer counts actual workers (unripe, spoiled, Flavor/color affected. NCR
present at the sorting table. acaros-damaged). Below 3 for under-staffing. Production
workers = sorting gaps = supervisor must add workers
defective fruit passing immediately.
through.

3 Unripe ≤ 2 ≤ 2 per From each random 20-fruit sample Unripe fruit has: lower Brix If >2 unripe per sample:
20-fruit taken from the sorting belt, count (sugar), higher acid, poor reject the incoming lot OR
sample how many are visibly unripe (green, color, bitter flavor. Even small increase sorting intensity.
hard, not fully orange colored). percentages significantly NCR required. Inform
affect final concentrate procurement.
quality.

4 Spoild = 0 ZERO TOLE Count of visibly spoiled/rotten fruit Any spoiled fruit introduces: IMMEDIATE STOP of fruit
RANCE in the 20-fruit sample. This means pathogenic bacteria, mold intake from that lot. Hold
fruit showing mold, fermentation, mycotoxins, off-flavors, and entire lot. NCR + Root Cause
internal rot, or complete yeast contamination into the Analysis. Supplier
deterioration. process. This is a food safety notification. Potential
hazard, not just quality. regulatory reporting.

5 Acaros = 0 ZERO TOLE Count of Acaros mites (tiny Acaros presence indicates: Same as Spoild = 0 violation.
RANCE spider-like fruit mites) visible on fruit poor agricultural practices, Immediate lot hold. NCR.
surface in the 20-fruit sample. inadequate pre-harvest Supplier rejection. Possible
Requires magnification or trained treatment, hygiene risk. Mites full lot destruction.
eye. in food = foreign body
contamination = regulatory
violation.

6 Broken ≤ 2 ≤ 2 per Count of mechanically Broken fruit: loses juice >2 broken per sample:
sample broken/crushed fruit in the 20-fruit during transport (yield loss), investigate
sample. Broken fruit has exposed oxidizes faster (color/flavor), transport/handling. Increase
pulp that oxidizes rapidly and provides bacterial growth sorting. NCR to
provides entry points for substrate. Too many = procurement. May indicate
contamination. handling/transport damage. mechanical issue with
receiving equipment.

7 Overall NLT ≥ 8 out of 10 A composite quality score assigned Provides a single quantitative <8/10: Reject lot OR process
8/10 to the fruit lot after all individual summary for the raw material with exception approval from
checks. Combines ripeness, color quality. Allows trending QC Manager. Increased
uniformity, size, external analysis across batches and monitoring required. NCR +
appearance, absence of defects. suppliers. supplier feedback.

8 Sprayers All All Open (✓) Verification that ALL spray nozzles Washing sprayers are the Block nozzle found: STOP
Open in the fruit washing/rinsing zone are primary decontamination step line, clean/replace nozzle,
open and functioning. Engineer for fruit surface. A blocked restart only when all
physically checks each nozzle for nozzle = incomplete washing confirmed open. NCR. Never
flow and coverage. = bacteria/pesticide residues run with blocked sprayer.
pass through.

9 Strainer Clean & Physical inspection of the in-line Strainer removes seeds, Damaged strainer:
(OPRP2) Undamaged strainer/filter mesh. OPRP = large pulp pieces, peel IMMEDIATE STOP.
Clean & Operational Pre-Requisite Program. fragments, and foreign bodies Replace. Document. NCR.
Check for tears, blockages, buildup, from juice. Damaged strainer Check all product produced
Undamaged
or corrosion. = bone-hard seed fragments since last good check —
in juice = customer may require hold.
complaints + safety risk.
1 Fiensher Clean & The 'finisher' is a rotating screen Controls final texture and pulp Damaged finisher: Hold
0 (OPRP3) Undamaged that refines juice separation, level of juice. Damaged product. Check Brix and pulp
Clean & controlling pulp content percentage. finisher screen = incorrect %. Issue NCR. Depending
OPRP3 means it's a monitored pulp % = product out of on severity, product may
Undamaged
prerequisite program. specification for FCOJ need reclassification or
category. rejection.

1 Paste Temp ≥ 80°C — Temperature measurement at the Pasteurization at ≥80°C IMMEDIATE LINE STOP.
1 (CCP1) Min CRITICAL pasteurization heater outlet. CCP1 destroys pathogenic Hold ALL product since last
80°C CONTROL = Critical Control Point 1. This is the organisms: Salmonella, good reading. Do NOT
POINT most important safety parameter in [Link], Listeria, and release any product. NCR
the entire process. heat-sensitive spoilage with CCP Deviation status.
organisms. Below 80°C = QC Manager + Plant
potential pathogen survival = Manager notification.
food safety emergency. Regulatory may need to be
informed. Full batch risk
assessment.

1 Cooling ≤ 65°C Temperature at outlet of plate heat If product enters Adjust cooling water flow. If
2 Temp Max exchanger (PHE) cooler. Product evaporator/filling above 65°C: can't cool below 65°C:
65°C must be cooled after pasteurization thermal stress damages investigate PHE fouling or
before evaporation/filling. flavor compounds, causes cooling water temperature
undesired Maillard browning, issue. NCR. Product may
affects color (yellowing), and have color/flavor deviation.
creates excess pressure in
filling tanks.

1 Separator 2% 2% Pulp by The centrifugal separator removes Pulp percentage defines the If pulp % is off: adjust
3 P.P in juice weight excess pulp from juice. The target product category and affects: separator speed. Product
pulp percentage in the process Brix readings accuracy, filling may not meet specification.
stream should be approximately pump behavior, final product Hold until pulp % confirmed.
2%. Check via lab measurement. texture, and customer NCR.
specification compliance.

1 Eva. Temp ≥ 75°C Temperature in the evaporator Sufficient evaporation Adjust steam pressure to
4 Min 75°C (eva) where water is boiled off to temperature ensures: correct evaporator. If can't maintain:
concentrate the juice. Must Brix achievement, microbial product Brix will be low.
maintain minimum temperature for safety during concentration NCR. Product on hold until
effective evaporation. step, and energy efficiency of Brix confirmed.
evaporation.

1 Brix Monitor Product-spe Refractometer reading of dissolved Brix defines the product: Low Brix: increase
5 cific target solids (primarily sugar) FCOJ must meet specific °Bx concentration (evaporation
concentration. FCOJ typically for legal definition and time/temp). High Brix: dilute
65°Bx. Measurement taken at customer specs. Also in blend tank. Both require
evaporator outlet. indicates concentration NCR. All product held until
efficiency and confirms Brix confirmed in range.
evaporation is working.

1 PE Bags Clean, No Visual inspection of polyethylene The bag is the final barrier Reject contaminated bags.
6 Clean & No Dust, No aseptic bags before filling. Check protecting product from Check entire batch of bags.
Dust Holes packaging materials in storage and environment. Contaminated NCR. Inspect storage
at point of use. bag = contaminated product. conditions. May indicate
Dust inside = physical storage area hygiene
contamination. Holes = loss problem.
of aseptic seal.

1 Drums Clean Clean, No Inspection of steel drums used for Rust = iron contamination of Reject drums. NCR. Return
7 & No Rust Rust, No filling. Check for: rust spots, dents, product. Previous residues = to drum supplier. Check
Damage previous product residues, cross-contamination. entire drum lot received.
damaged lids/gaskets. Damaged gaskets =
non-aseptic seal = product
spoilage in storage.
1 Pallets Clean Clean & Not Check wooden/plastic pallets for Broken pallets: risk of drum Remove broken pallets.
8 & Broken Broken cleanliness and structural integrity. falling, product damage, Clean or replace. Document.
worker injury. Dirty pallets:
pest attraction, possible
contamination transfer.

1 Store -18°C (±2°C Temperature check in the frozen FCOJ must be stored at If storage temp >-15°C:
9 Freezing acceptable) storage warehouse where filled -18°C to: prevent microbial alarm. Hold all product in
-18°C drums are stored. Record actual growth, halt enzymatic affected area. Investigate
temperature reading. degradation, maintain Brix refrigeration failure. NCR.
stability, and preserve color Product integrity
and flavor for 12-24 month assessment. May need
shelf life. destruction.
2.4 — Reading the Actual Data From Your IPC Report
Your IPC report from 29.04.2026 shows checks at 13:00, 14:00, 15:00, and 16:00. Let's analyze what was
actually recorded and what it tells us:

PARAMETER 13:00 14:00 15:00 16:00 ANALYSIS

3 checks passed. Gap at 15:00 — line may

Basin Fruit ✓ ✓ — ✓
have stopped.

Exactly at minimum. No buffer. Any absence =

Sorter N.O. 3 3 — 3
NCR.

Unripe ≤2 1 1 — 1 Good — well within limit of 2.

*15:00 reading looks like ~0 — needs

Spoild = 0 0 0 ~0* 0
verification.

Acaros = 0 0 0 0 0 Perfect. Zero tolerance maintained.

ALERT: 15:00 shows possible 5 —

Broken ≤2 0 1 ~5* 0
EXCEEDS limit of 2!

Overall NLT8 9.5 9 — 9 Excellent scores. Raw material quality is good.

ALERT: 79°C at 16:00 is BELOW 80°C

Paste Temp CCP1 — 82°C 80°C 79°C
minimum! CCP BREACH!

Cooling Temp — 61°C — 58°C Good — within ≤65°C limit.

66°C recorded (need to verify min 75°C

Eva. Temp — — — 66°C
requirement).

50°Bx — needs verification against FCOJ

Brix Monitor — — — 50
target spec.

■ CRITICAL FINDING: CCP1 Breach at 16:00

The Paste Temperature at 16:00 recorded 79°C — 1 degree BELOW the mandatory 80°C minimum. This
is a CCP1 deviation. Under HACCP rules, ALL product produced from the last good reading (80°C at
15:00) to correction of the temperature must be HELD and assessed. This triggers an IMMEDIATE NCR
with CCP Deviation classification. This is consistent with the notes showing production was stopped at
14:41.
2.5 — CCP (Critical Control Points): The Safety Gates
CCP stands for Critical Control Point. It is defined in the HACCP (Hazard Analysis and Critical Control Points)
food safety management system. A CCP is a step where a control measure can be applied that is essential
to prevent or eliminate a food safety hazard, or reduce it to an acceptable level.

CCP STEP HAZARD CRITICAL MONITORING CORRECTIVE ACTION

CONTROLLED LIMIT

CCP1 Pasteurization Pathogenic bacteria: Min 80°C at Continuous + STOP line. Hold product. QC
(Paste Temp) Salmonella, [Link], all times hourly record Manager. Full investigation.
Listeria monocytogenes

OPRP Strainer Physical hazard: Seeds, Clean & Visual check each STOP. Replace. Hold
2 peel, foreign bodies Undamaged hour product since last check.

OPRP Finisher Quality deviation: Clean & Visual check each Adjust or replace. Hold
3 Incorrect pulp % Undamaged hour product.
 3 SECTION 3 — FILLING REPORT: COMPLETE DEEP
ANALYSIS

3.1 — Purpose and Legal Importance

The Filling Report is the production ledger. While the IPC Report tracks the PROCESS, the Filling Report
tracks the PRODUCT. Every single drum (barrel) that gets filled receives an entry in this report. It creates an
unbroken traceability chain: if a customer in Europe complains about drum serial number 00453, you can
open the Filling Report and know EXACTLY when it was filled, at what temperature, from which tank, who
supervised it, and what the batch number was.

This is the foundation of product recall capability. Without a complete Filling Report, you cannot perform a
targeted recall — you would have to recall the entire production run.

3.2 — Every Column: Detailed Explanation

COLUMN FULL MEANING WHAT TO WRITE WHY IT EXISTS

Shift Which work shift filled this A or B (A = morning, Identifies which team is accountable. If problems
drum B = night) found later, you know who to interview.

Filling Time Time filling of this drum e.g., 14:30 Combined with 'To', calculates filling duration.
FROM started Abnormal duration = pump issue or blockage.

Filling Time Time filling of this drum was e.g., 14:44 Duration check. FCOJ drum fill should take consistent
TO completed time based on flow rate.

Tank (A, B) Which storage/buffer tank A or B Critical for traceability. If Tank B has an issue, only
the product came from drums filled from Tank B are affected.

Weight (KG) Actual net weight of product e.g., 249, 251 Verifies correct fill weight for customer payment and
in drum (FCOJ target: 250 label accuracy. Over/under = NCR.
±2kg)

Washing & Was the drum cleaned and ✓ or X Unwashed drum = contaminated product. This is a
Disinfect sanitized before filling? pre-requisite food safety requirement.

Filling Temp Temperature of product at °C reading Too hot = aseptic integrity risk. Too cold = viscosity
point of filling issues. Must be within spec.

Serial NO. Starting serial number of e.g., 00450 Together with 'To', identifies the exact drums in this
From drum batch filled filling run.

Serial NO. To Ending serial number of e.g., 00460 Enables fast isolation of specific drums during recalls.
drums in this run

Quantity Number of drums filled in e.g., 10 Quick count verification. Should match (To - From +
this entry 1).

Who Name/ID of quality engineer Employee name or Legal accountability. The person who signed off is
who supervised ID responsible for this entry's accuracy.
 Remark Any observations, Free text Captures information that doesn't fit other columns.
deviations, or notes Partial fills, equipment issues, etc.

3.3 — Weight Tolerances: Why ±2kg Matters

PRODUCT TARGET WEIGHT ACCEPTABLE RANGE BELOW RANGE ABOVE RANGE

FC (Concentrate) 190 kg 188 – 192 kg Short-fill → customer claimOverfill

+ NCR → cost loss + NCR

FCOJ (Orange Juice Conc.) 250 kg 248 – 252 kg Short-fill → customer claimOverfill
+ NCR → cost loss + NCR

FCLJ (Lemon Juice Conc.) 245 kg 243 – 247 kg Short-fill → customer claimOverfill
+ NCR → cost loss + NCR
 4 SECTION 4 — CHECKLIST REPORT: STRUCTURE &
IMPORTANCE
The Checklist (also called Line Clearance or Pre-Startup Checklist) is completed BEFORE production starts
and sometimes AFTER shutdown. It is fundamentally different from the IPC Report because it verifies the
ENVIRONMENT, not the process parameters.

CLEANING & SANITATION

All contact surfaces cleaned Ensures no previous product or cleaning chemical residues ■ PASS ■ FAIL

Sanitizer correctly diluted and applied Incorrect dilution = ineffective or harmful ■ PASS ■ FAIL

Rinse water confirmed clean Sanitizer residue in product = contamination ■ PASS ■ FAIL

CIP (Clean-In-Place) cycle completed For tanks and pipelines ■ PASS ■ FAIL

EQUIPMENT READINESS
All strainers/screens checked and
Pre-verified before OPRP2/OPRP3 on IPC ■ PASS ■ FAIL
intact

All seals and gaskets inspected Failed seal = contamination entry point ■ PASS ■ FAIL

Instrumentation calibrated
Inaccurate readings = false compliance ■ PASS ■ FAIL
(thermometers, Brix meters)

Sprayers checked and unclogged Pre-verified before production start ■ PASS ■ FAIL

PACKAGING MATERIALS
PE bags inspected: clean, no holes Final product barrier ■ PASS ■ FAIL

Drums inspected: clean, no rust Packaging integrity ■ PASS ■ FAIL

Correct batch/lot labels prepared Traceability requirement ■ PASS ■ FAIL

PERSONNEL & HYGIENE

All workers have proper PPE (gloves,
Personal hygiene = food safety ■ PASS ■ FAIL
hairnets, coveralls)

No unauthorized persons in
GMP requirement ■ PASS ■ FAIL
production area

Health declarations signed (no illness) Sick workers = contamination risk ■ PASS ■ FAIL

UTILITIES
Steam pressure at correct level Required for pasteurization ■ PASS ■ FAIL

Cooling water temperature verified Required for cooling step ■ PASS ■ FAIL

Compressed air filters checked Air contacting product must be clean ■ PASS ■ FAIL
Freezer storage temperature confirmed
Product integrity ■ PASS ■ FAIL
at -18°C
 5 SECTION 5 — HOW TO WRITE AN NCR
(NON-CONFORMANCE REPORT)

5.1 — What Triggers an NCR?

An NCR (Non-Conformance Report) is raised whenever any measured or observed parameter falls outside
its defined acceptable range. It is NOT optional — it is a mandatory documented response to any deviation.
The purpose is twofold: immediate corrective action, and long-term root cause elimination.

TRIGGER CATEGORY EXAMPLES NCR SEVERITY

CCP Deviation Paste Temp <80°C Eva Temp <75°C CRITICAL — Stop production
immediately

OPRP Failure Damaged strainer Blocked sprayer MAJOR — Stop and repair before
continuing

Raw Material Rejection Spoild >0 Acaros >0 Overall <8/10 MAJOR — Reject lot, notify
supplier

Process Parameter Cooling Temp >65°C Brix out of range Pulp % off MODERATE — Adjust and monitor
Deviation closely

Packaging Deviation Drum weight out of ±2kg Rusty drum PE bag with MODERATE — Reject affected
hole units

Documentation Gap Missed hourly check Empty required field No MINOR — Correct and retrain
signature

Storage Deviation Freezer >-15°C MAJOR or CRITICAL depending on

duration

5.2 — NCR Template: Every Field Explained

NCR Number Sequential number. e.g., NCR-2026-0047. Never reuse Auto-assigned or sequential
numbers. This is your filing reference.

Date & Time When the non-conformance was DETECTED, not when the 29/04/2026 — 16:00
NCR was written.

Product Full product name and code. FCOJ

Batch Number The batch affected by this deviation. 290426/OC

Detected By Name and role of the person who found the issue. Quality Engineer Name

Location / Step Exactly where in the line the deviation occurred. Pasteurizer — CCP1
Description of Factual description: what was found, what was expected. No Paste Temp recorded 79°C at
Non-Conformance opinions — only facts. 16:00. Critical limit is 80°C
minimum.

Evidence Reference to the IPC Report entry, Brix readings, photos, lab IPC Report 29.04.2026, 16:00
results. column, Paste Temp row

Affected Product / How much product is at risk? What serial numbers? Which All drums filled from 15:00 to
Quantity drums? 16:15 — approx. drums
00445-00467

Immediate Action What was done RIGHT NOW to stop the problem spreading. Line stopped at 14:41. Product
(Containment) placed on HOLD. Tags applied to
affected drums.

Root Cause Analysis WHY did this happen? Use 5-Why method. Not 'human error' — 5-Why analysis: Why 79°C?
dig deeper. Steam valve partially closed.
Why? Valve actuator failed. Why
not detected? No alarm on valve
position. Why no alarm? PM
schedule gap.

Corrective Action What permanent fix prevents recurrence? 1) Repair valve actuator. 2) Add
valve position alarm. 3) Add valve
to PM schedule.

Product Disposition What happens to the held product? HOLD → Lab test (pathogen
screen) → If pass: Release with
deviation noted. If fail: Destroy.

Verification How do you confirm the corrective action worked? Next 5 hourly readings must show
≥80°C. QC Manager sign-off
required.

Signatures Detected by / QC Manager / Plant Manager / Date closed. All required for NCR to be 'closed'
5.3 — Real NCR Example Based on Your Batch 290426/OC
FIELD CONTENT

NCR Number NCR-2026-0047

Date / Time 29/04/2026 — 16:00 (detected) | Written: 16:15

Product / Batch FCOJ / Batch 290426/OC

Severity CRITICAL — CCP1 Deviation

Detected By Quality Engineer on duty (Shift A)

Location Pasteurizer outlet — CCP1 monitoring point

Non-Conformance Paste temperature measured at 79°C. Critical limit: minimum 80°C. Deviation = -1°C below limit.

Evidence IPC Report 29.04.2026, column 16:00, row 'Paste Temp CCP1' = 79°C.

Affected Product All product from last confirmed good reading (15:00 = 80°C) to line stop (14:41 noted in action
log). Drums on HOLD pending investigation.

Immediate Action 1. Production line STOPPED at 14:41 (per Action/Notes section of IPC). 2. All drums from
affected window tagged as HOLD — DO NOT RELEASE. 3. QC Manager and Plant Manager
notified. 4. Thermometer cross-checked with calibrated reference thermometer.

Root Cause To be determined. Possible: steam pressure drop, valve issue, or thermocouple calibration drift.
(preliminary)

Corrective Action 1. Identify and fix root cause before restart. 2. Re-verify pasteurizer reaches and HOLDS ≥80°C
for minimum 5 minutes. 3. Only restart after QC Manager written approval.

Product Disposition HOLD. Microbiological testing to be performed on held product. Decision pending test results.

Status OPEN — Awaiting root cause confirmation and product test results.
 6 SECTION 6 — HOW TO JUDGE: IS PRODUCTION
RUNNING CORRECTLY?

The Quality Judgment Framework

As a quality engineer, you must make real-time judgments about whether to continue or stop production. This
requires understanding the hierarchy of parameters and knowing which deviations are catastrophic versus
manageable.

■ GREEN — Production OK ■ YELLOW — Monitor Closely ■ RED — Stop Production

• All CCP readings within limits • Sorter exactly at minimum (=3) • CCP1 (Paste Temp) <80°C
• Sorter = 3+ workers • Unripe approaching limit (=2) • Spoild >0 in sample
• Spoild = 0, Acaros = 0 • Cooling temp 62-65°C • Acaros >0 in sample
• Brix within target range • Brix slightly low/high • Strainer damaged
• Drum weights within ±2kg • One drum weight at tolerance edge • Storage temp >-15°C
• All ✓ marks confirmed • Minor documentation gap • Brix completely off spec
• Storage at -18°C • Drum weight out of ±2kg range
• All OPRP checks passed ACTION: Increase frequency of checks. Alert supervisor. Prepare to escalate.
ACTION: Stop. Hold. NCR. Notify. Investigate.

Assessing Your Batch 290426/OC — Final Judgment

PARAMETER FOUND LIMIT STATUS ACTION NEEDED

Raw Material Quality Overall 9-9.5/10 ≥ 8/10 ✓ PASS None

Unripe fruit 1 per sample ≤2 ✓ PASS None

Spoiled fruit 0 all readings =0 ✓ PASS None

Acaros 0 all readings =0 ✓ PASS None

No buffer — alert
Sorter staffing 3 workers ≥ 3 (NLT 3) ■ MINIMUM
supervisor

NCR CRITICAL — Line

Paste Temp CCP1 79°C at 16:00 ≥ 80°C ✗ FAIL — CCP BREACH
stopped

Cooling Temp 58-61°C ≤ 65°C ✓ PASS None

Clean, no
PE Bags Not recorded ? UNKNOWN Verify and record
dust

Drum Weight Not filled in report 250 ±2kg ? UNKNOWN Complete Filling Report

HOLD — Pending CCP NCR required. Do not

Overall Verdict — —
resolution release.
 7 SECTION 7 — DECISION FLOW: WHAT TO DO
WHEN SOMETHING GOES WRONG
When you detect a deviation during your hourly IPC check, you must follow a structured response. The
speed and quality of your response determines whether a minor issue becomes a major recall.

During your hourly check, you record a value outside limits — OR you observe
STEP 1: something wrong visually. Do NOT wait until the next check. Act immediately when you
DETECT
see it.

Is this a CCP deviation? → STOP THE LINE NOW. Is this a major deviation? → STOP
STEP 2: THE LINE. Is this moderate? → Can continue but must correct immediately. HOLD all
CONTAIN
suspect product. Apply physical HOLD tags to drums. Do not let anything leave the area.

Immediately notify: QC Manager, Production Supervisor, Plant Manager (for CCP

STEP 3: NOTIFY deviations). Use phone/radio — do not wait until end of shift. Time stamps matter for
traceability.

STEP 4: Investigate: What exactly went wrong? When did it start? What is the root cause? Use
INVESTIGATE 5-Why methodology. Document everything. Cross-check instruments (calibration).

STEP 5: WRITE Open the NCR form. Fill every field — do not leave blanks. Classify severity. Document
NCR containment and root cause. Get required signatures.

STEP 6: Implement the fix. Verify it worked (3-5 consecutive readings within limits). Get QC
CORRECT & Manager approval to restart. Document restart time.
VERIFY

STEP 7: CLOSE Once corrective action is verified and product disposition is decided, close the NCR. File
NCR it in the NCR register. Schedule follow-up in 30 days to verify recurrence prevention.
8 SECTION 8 — QUICK REFERENCE CARD (Print &
Keep)
PARAMETER STANDARD DEVIATION ACTION

Basin Fruit Clean ✓ Stop intake. Clean. Record.

Sorter Workers ≥ 3 (NLT 3) Call more workers immediately. NCR if delayed.

Unripe Fruit ≤ 2 / 20 fruit Reject lot if >2. Notify procurement. NCR.

Spoiled Fruit = 0 (ZERO) STOP fruit intake. Hold lot. NCR-MAJOR.

Acaros = 0 (ZERO) STOP fruit intake. Hold lot. Reject supplier lot. NCR-MAJOR.

Broken Fruit ≤ 2 / 20 fruit Investigate handling damage. Increase sorting. NCR if persistent.

Overall Quality ≥ 8/10 If <8: reject or exception approval. NCR.

Sprayers All Open ✓ STOP. Unblock/replace nozzle. Verify all open. Restart.

Strainer (OPRP2) Clean & Undamaged STOP. Replace strainer. Hold product since last check. NCR.

Finisher (OPRP3) Clean & Undamaged STOP. Replace. Check pulp %. NCR.

Paste Temp (CCP1) ≥ 80°C ← CRITICAL STOP LINE. HOLD ALL PRODUCT. NCR-CRITICAL. Notify management.

Cooling Temp ≤ 65°C Increase cooling water. Investigate PHE. NCR if persistent.

Separator Pulp ~2% P.P. Adjust separator speed. Hold product. Check Brix. NCR.

Eva. Temp ≥ 75°C Increase steam. Check Brix at outlet. NCR if Brix affected.

Brix Product spec (FCOJ: ~65°Bx) Adjust concentration. Hold product. Retest. NCR.

PE Bags Clean, No Dust Reject batch of bags. Inspect storage. NCR.

Drums Clean, No Rust Reject drum. Return to supplier. NCR.

Drum Weight 250 ±2kg (FCOJ) NCR. Investigate filling equipment. Reweigh.

Storage Temp -18°C (±2°C) Alarm. Investigate refrigeration. Assess product. NCR-MAJOR.

REMEMBER: The Golden Rule of Quality Control

When in doubt — HOLD THE PRODUCT. You can always release held product after verification. You can
NEVER un-release a contaminated product that has already reached a customer. The cost of a hold is a
few days and some testing. The cost of a recall is millions of dollars, brand damage, and potential criminal
liability under food safety law.