Training materials for performing carcase Meat Hygiene Assessments on skin on goats

Transcription

1 Training materials for performing carcase Meat Hygiene Assessments on skin on goats These materials can be used to support the delivery of the Unit of competency AMPA3072 Perform carcase Meat Hygiene Assessment

2 National Meat Industry Training Advisory Council (MINTRAC) 2016 All rights reserved. These materials were written and updated in 2016 with the assistance of funding provided by Meat and Livestock Australia (MLA) and the Australian Meat Processor Corporation (AMPC). This work is copyright, but permission is given to trainers and teachers employed by Australian Registered Training Organisations to make copies for use within their own training organisation or in a workplace where the training is being conducted. This permission does not extend to the making of copies for use outside the immediate training environment for which they are made, nor the making of copies for hire or resale to third parties. For permission outside of these guidelines, apply in writing to MINTRAC. First published 2016 Published by National Meat Industry Training Advisory Council Ltd 2/150 Victoria Road DRUMMONE NSW 2047 Telephone Facsimile Web Site: mintrac.com.au Disclaimer This training material has been prepared with the assistance of industry sources and by reference to current legislation. However MINTRAC accepts no responsibility for any consequence of oversight, misinterpretation or error in the material. The material does not purport to be a substitute for your own legal obligations and MINTRAC recommends that it be used only as a guide to training. Currency of training can be achieved by using proper enterprise work instructions and standard operating procedures combined with appropriate reference to current local, state and federal legislation. ii MINTRAC 2016

3 Training support materials for monitors performing carcase MHA on skin-on goats Table of contents Training support materials for monitors performing carcase Meat Hygiene Assessment on skin on goats... 5 Meat Hygiene Assessment... 5 Objective methods for the monitoring of carcases... 5 Overview... 5 PDCA in brief... 6 Basic concepts... 7 Population... 7 Sample... 7 Statistic... 7 Normal distribution... 7 Variation... 8 Statistical Process Control (SPC)... 8 Corrective action/prevention of recurrence... 8 Preventive action... 8 Check the Checker (CTC)... 8 Carcase monitoring... 9 Background... 9 Aims... 9 Scope Procedure Carcase assessment Sampling Monitoring Monitoring frequency Minimum requirements - assessment of samples Defect criteria What is physical contamination? What does physical contamination look like? How do monitors scan a carcase? Defect ratings Recording defects Corrective action-carcases Zero tolerance and carcases CCP monitoring and MHA Bibliography Additional resources... 24

4 Table of contents Assessment materials for AMPA3072 Perform carcase Meat Hygiene Assessment Assessment tools Evidence guide AMPA3072 Perform carcase Meat Hygiene Assessment Workplace referee's report AMPA3072 Perform carcase Meat Hygiene Assessment Test or quiz AMPA3072 Perform carcase Meat Hygiene Assessment Answer sheet (for assessor use only) On-the-job demonstration with assessor observation AMPA3072 Perform carcase Meat Hygiene Assessment Record of completed assessment AMPA3072 Perform carcase Meat Hygiene Assessment iv MINTRAC 2016

5 Training support materials for monitors performing carcase MHA on skin-on goats Training support materials for monitors Error! No text of specified style in document. on skin on goats These materials can be used for training in Error! No text of specified style in document.72 Error! No text of specified style in document. in the Certificate III Meat Processing or as unaccredited in-house training. Meat Hygiene Assessment Objective methods for the monitoring of carcases Overview Meat Hygiene Assessment has been designed to be the monitoring, recording, corrective action and verification guide for HACCP and Good Hygiene Practice (GHP) in the Australian red meat industry. Meat Hygiene Assessment provides three controls for maintaining safe meat: process monitoring, which provides measured controls over operations carcase monitoring, which provides measured control over carcase hygiene trend analysis, which provides on-going control over both processes and product. To help understand where MHA fits into the overall quality structure it is worth considering it in light of the Plan, Do, Check, Act (PDCA) cycle. The PDCA cycle is a control and continuous improvement methodology incorporated in various well known management systems. For example: TQM Lean Manufacturing ISO Standards (ISO 9001:2000, 22000:2005 for example) Meat Industry Approved Arrangements.

6 Training support materials for monitors performing carcase MHA on skin-on goats PDCA in brief PLAN: May include objectives, KPI s, HACCP Plans, pre requisite programs, work instructions, legislation, importing country requirements. DO: Basically implementation of the plan. Includes activities such as supervision, training, trialling plans, validation activities, capability studies. CHECK: Is the first component of MHA. Includes: Process and product monitoring systems General verification activities Check the Checker, audit etc. Trend analysis Statistical Process Control (SPC). ACT. The second component of MHA which consists of taking action to control and improve both products and processes. Includes: corrective action preventive action associated documentation. By using PDCA as a model to help us understand the role MHA plays it is clear that MHA is not the whole mechanism used to control and improve processes and products. It is however a critical component of the checking and acting functions. In summary Meat Hygiene Assessment provides: 1. Two tools for measuring the effectiveness of controls implemented for maintaining safe meat: Process Monitoring, which provides measured assessment of operations Product Monitoring, which provides measured assessment of product hygiene 2. Several action tools designed to bring out of control product and processes into control and to provide ongoing improvement, including: corrective action and associated prevention of recurrence as appropriate preventive action data analysis, including: Trend analysis Statistical Process Control techniques. 6 MINTRAC 2016

7 Training support materials for monitors performing carcase MHA on skin-on goats Basic concepts Population Population is the total of all items under investigation. For example if 5000 units are to be produced within a given time frame the total number may be considered the population. Within this document a population is generally referred to as a lot. The production for any given shift can be considered as one or more lots. Sample A sample is that part of a population selected for monitoring or analysis. It is usual and probably desirable not to subject the entire population to testing/monitoring. Therefore a sample is taken. In this case perhaps 80 units are chosen. The outcome from checks performed on that eighty will form the basis of any decisions made about the Sample size needs to be statistically valid or else conclusions drawn from the sample may well be misleading. In general the larger the sample size the more accurate the statistics. Statistic A statistic is a feature of a sample and is calculated to help describe a characteristic of a population, i.e., Product defect rating, Chemical Lean testing results etc. Normal distribution Normal distribution is the term used to describe the appearance of many quality characteristics examined in a quality environment. It provides the basis for classical statistical inference. Graphically the normal distribution appears as a bell shaped curve. The normal distribution is important as it provides the basis for statistical inference. Its properties include: it is bell shaped and generally symmetrical in appearance

8 Training support materials for monitors performing carcase MHA on skin-on goats provides measures of central tendency Mean, Median and Mode its practical range equals the Mean ± 3 standard deviations. Variation Variation is the term is used to describe the degree of spread from the mean exhibited by the data under investigation. Many measures are used to help describe this spread including standard deviation (σ) and range. Statistical Process Control (SPC) SPC involves the comparison of process output with a standard and in so doing provides an understanding of the variation occurring in the process. Many tools are used including X and R, U and C charts to name a few. Corrective action/prevention of recurrence This is the action taken to control and eliminate the cause of non-conformities in order to prevent recurrence. Includes the following general steps: identification and control of affected product/process rework of affected product, where applicable identification of the cause of the failure/non conformity action taken to prevent recurrence of the failure. (note this may depend on the risk associated with the failure) verification that action taken has been effective maintenance of corrective action documentation. Preventive action Preventative action is action taken to eliminate the causes of potential non conformities in order to prevent them from occurring. Note that we have separated corrective and preventive action in order to help fully appreciate the value that preventive action has in the improvement process. HACCP can be seen as a powerful preventive tool. Trend graphs, SPC charts, capability studies can also provide information about product/process performance and allow action to be taken prior to failure. Check the Checker (CTC) CTC is a verification activity unique to MHA. It consists of senior company staff checking the accuracy and effectiveness of company monitoring activities on a predetermined basis. As a lot of decisions are made based on monitoring information it is 8 MINTRAC 2016

9 Training support materials for monitors performing carcase MHA on skin-on goats an important step in ensuring this information is as accurate as possible. Note that especially in the case of product CTC findings of the checker should not be added to the monitor s findings. Australian Government- Agriculture also performs a check the checker activity. Carcase monitoring Background Carcase monitoring measures end point product defects, and uses the results to verify the effectiveness of the sanitary process. Aims The objectives of the product monitoring component of this program for meat hygiene assessment are: to confirm that physical standards of meat hygiene have been satisfied to verify that the process is being conducted in accordance with documented work instructions, SOP s or other forms of control. to identify: - threshold levels for the triggering of remedial action when monitoring indicates that product standards have not been met (corrective action) - trends in these outputs over time and to reconcile product standards with the results of process monitoring (Verification). See below:

10 Training support materials for monitors performing carcase MHA on skin-on goats Scope MHA carcase monitoring is undertaken at all export meat establishments in the following categories: abattoirs, including integrated establishments independent boning rooms meat processing establishments. MHA carcase monitoring is undertaken regardless of overseas country listings held by individual establishments. Carcase monitoring for skin-on goats are assessed after the final trim using the target defect ratings designed for after the wash. Procedure Carcase assessment Assessment of carcases after final trim before the final wash The normal sampling level delivers 95% confidence that defects will be identified. When two consecutive average monitorings of product produced in a shift at the normal sampling level are rated marginal, the intensified level of sampling is adopted. These is dealt with later in these notes. This level delivers 98% confidence that defects will be identified. When at least five consecutive average monitorings of carcases produced in a shift at the normal sampling level are rated acceptable, monitoring can move to the reduced level of sampling. This level delivers 85% confidence. Assessment of carcases after the final wash Where no scoring defects are encountered during at least five consecutive average monitorings of product produced in a shift after leaving the slaughter floor, the intensity of monitoring can be reduced to every second day. When average monitoring of carcases produced in a shift indicates any reappearance of scoring defects, the normal level of sampling is resumed. Boning For assessment of trimmed carcases: examine ten carcases per run per line to assess the effectiveness of trimming. Use the same defect criteria used for product monitoring an acceptable target defect rating should be 0.5. Defects identified during carcase monitoring should be removed immediately. 10 MINTRAC 2016

11 Training support materials for monitors performing carcase MHA on skin-on goats A zero tolerance detection on carcases selected for monitoring after pre-boning tri, automatically rates this lot as unacceptable. It also triggers immediate corrective action in the form of increased monitoring and adjustment of the operation, regardless of the conformity index for the boning process. The affected lot is subject to further investigation and corrective action as described in the section on corrective action. Hot boning Where carcases are passing directly from the slaughter floor to the boning room, it may not be possible to re-trim a lot assessed as unacceptable or two consecutive lots assessed marginal on the slaughter floor. In these cases, lots failing assessment on the slaughter floor are subject to a double intensity of carton meat sampling (i.e. 2 x 13.5 kg from each product type from separate cartons at least every 30 minutes). These samples are recorded separately. This increased level of carton meat assessment is continued until five consecutive average monitorings from carcases are rated acceptable, or an intensified final trim on the slaughter floor or at the pre-boning trim (agreed between the Company and the Australian Government- Agriculture supervisor) is employed until five consecutive average monitorings from carcases are rated acceptable. Hot bagging of carcases Lots bagged straight from the slaughter floor and assessed unacceptable by slaughter floor assessment are subject to further assessment and appropriate corrective action when necessary. The further carcase assessments continue until five consecutive average monitorings of carcases are rated acceptable at slaughter floor assessment, or Load out an intensified final trim on the slaughter floor (according to the established program agreed between the company and the Australian Government- Agriculture supervisor) is employed until five consecutive average monitorings of the carcases produced are rated acceptable at slaughter floor assessment. All carcases shall be assessed using the after the wash criteria (see Table 14) prior to load out. Where there is no final wash carcases shall be assessed using the before the wash criteria. Where appropriate this shall be performed prior to bagging or telescoping. Marginal and unacceptable lots shall be trimmed in accordance with the corrective action requirements for carcases

12 Training support materials for monitors performing carcase MHA on skin-on goats Load in to independent boning rooms All carcases entering independent boning rooms and meat processing establishments shall be assessed using the after the wash criteria prior to boning. Samples shall be assessed from all different establishments of origin and all individual loads. Marginal and unacceptable lots shall be trimmed in accordance with the corrective action requirements for carcases and details of defects reported to the establishment of origin via an Unsatisfactory Transfer of Meat (UTM) Report. It is expected that as a minimum a UTM would be generated whenever a marginal or unacceptable load is received. Note: It may not be value adding when the feedback provided to supplying establishments includes an UTM report for defects found past the normal monitoring and trimming controls applied at the independent establishment. Sampling Sample units are dependent on the species of stock being processed. For goats a whole carcase is the sample Unit. The minimum number of sample units required to be examined for a statistical assessment of product is dependent on the number of items processed. Sample Size Total number Intensified Normal Reduced of animals level level level in a lot > Sample numbers at different production levels have been derived from the Australian Standard AS , Sampling Procedures and Tables for Inspection by Attributes. As noted there are three levels of sample size selected for monitoring - Normal, Intensified and Reduced. There are rules that determine which sample size needs to be selected. These are known as shifting rules and are applied according to product performance. 12 MINTRAC 2016

13 Training support materials for monitors performing carcase MHA on skin-on goats Sample size shifting rules Monitoring Carcase assessment through monitoring is a uniform method which objectively determines whether a preset quality level has been achieved. The preset quality level is defined in the defect ratings table dealt with later in this section. The program assumes that a carcase identification system is available at an establishment to differentiate between lots. It is recommended that: the selection of samples be as random as possible large production runs during a shift should be broken into a number of lots to: facilitate a practical approach to managing corrective action and improve information available for improving processes. where the lot concept is adopted as an option, lots should be defined in the company s MHA Standard Operating Procedure (SOP): "A production lot is the number of animals over which a monitoring sequence is conducted and from which a sample is drawn. It may represent the entire production for a shift or any part thereof," when there is significant variation within a lot (for example, large billies, kids and nannies, domestic and rangeland goats etc), monitoring should be spread across the entire lot. In these cases, increasing the number of lots monitored could also be considered. Note that where lots are selected on the basis of variation that exists in incoming stock the company will generate information that assists improvement activities. This practice could be considered to be best practice. Where

14 Training support materials for monitors performing carcase MHA on skin-on goats this approach is not implemented the company may be accepting a compliance only approach lots can be adjusted daily to reflect changes in the category or type of slaughter stock in establishments where there is a small throughput for a particular species, the production lot will most likely be the entire kill during a shift. This approach, however, has implications for corrective action, i.e. the whole day s production will need to be subjected to corrective action independent boning rooms treat loads from different abattoirs as separate lots. Monitoring frequency Monitoring is conducted at the frequencies set down in the following table: Monitoring frequencies Company Monitors A minimum of once every shift spread over the entire shift or several lots as elected. QA Managers (check the checker) Where the company has an approved arrangement the check the checker verification frequency shall be once per week. Minimum requirements - assessment of samples Facilities must be available and adequate to allow a thorough examination of all surfaces of the sampled carcases and to perform corrective action as necessary. Consideration should be given to: lighting intensity, as measured by a calibrated light meter. There is a legal requirement to be at a minimum of 600lux. Practice indicates that twice this intensity at the darkest inspection point should be considered. ou may not find defects at the legal minimum but many customers use high intensity light so they may well find what you miss! adequate space should be provided to allow for a complete examination sufficient time must be allocated to ensure a thorough examination of the carcase / side is performed and consistency is maintained sharp knife, hooks and rulers as appropriate 14 MINTRAC 2016

15 Training support materials for monitors performing carcase MHA on skin-on goats a table or stand for temporary storage of defects trimmed from the sample unit also useful for holding monitoring forms steriliser and hand wash facilities located nearby inspection point design to facilitate easy inspection of all surfaces. General requirements Assessment must be performed in a consistent manner using scanning lines. The issue of consistency is critical to monitoring outcomes especially so where decisions are being made based on monitoring results. If we are not consistent then we may merely be reacting to changes in monitoring consistency and not to the process change we may believe has occurred. Monitoring staff must be well trained and have regular sight tests. Defect criteria A number of physical, biological and sometimes chemical food safety hazards may be visually detected during carcase monitoring activities. What is physical contamination? Contamination is anything that should not be on the carcase. Physical contamination is visible contamination on the meat and includes: rust and grease rail dust hair bruises scurf pizzle butts foreign objects pieces of offal attached pathology or diseased material ZTs. Zero Tolerance contaminations are: faeces ingesta urine (in some plants) milk.

16 Training support materials for monitors performing carcase MHA on skin-on goats The following table provides some examples of defects that may be encountered during skin on goat carcase assessment. Zone Area Included Common Defects Hock hock, shank, hook hole hair, scurf, grease, rail dust, stains, Hindquarter outside tail area, back, flank rust, grease, hair, wool, hide, bruises, scurf, faeces, pizzle butts, inoculation abscesses Forequarter outside plate, ribs, chuck, neck, outside brisket, fore shank hair, grease, stains, nodules, bruises, grass seeds, scurf, ingesta Forequarter inside diaphragm, thorax, spine, neck, jugular groove, inner forearm, end of shank, brisket, pleura hair, hide, grease, stains, clots, bruises, broken ribs, ingesta, pieces of trachea and lung Hindquarter inside inside round, aitch bone, pelvic canal, spine, cod fat, lumbar area, kidney, ovary, abdominal surfaces, pizzle, rectal mucosa, peritoneum hair, grease, rust, faeces, hanging fragments, blood clots, remnants of organs, mature udder fragments, bruises What does physical contamination look like? Zero Tolerance (ZT) contamination Physical contamination is visible contamination on the meat. Zero Tolerance contaminations are those physical contaminants which make the product unfit for human consumption in overseas markets. However other physical contamination can easily be mistaken or interpreted as ZTs. For this reason it is essential that all physical contamination is removed. Overseas markets consider excreta, ingest and milk contamination as ZTs and most plants in Australia also treat urine as a ZT. Identifying and eliminating these contaminants is important because they can carry bacteria which make people sick and represent a real risk to consumer health. Excreta Excreta can be seen as smears of black, green or yellow on a carcase. It can also appear as black pellets in the channel or on the carcase. However smears of grease and oil can also be interpreted as ingesta and must be trimmed. Similarly small blood filled capsules can be found in the pelvic channel and these are easily mistaken for excreta. Bruising in the pelvic channel in nannies that recently kidded may appear as a 16 MINTRAC 2016

17 Training support materials for monitors performing carcase MHA on skin-on goats brown smear also. If the bung is not sealed properly pellets may be found in the channel and can be caught on other parts of the carcase. Carcase MHA monitors will find excreta mainly on the hindquarter but it can occur anywhere on the rest of the carcase. Ingesta Ingesta is gut content that has leaked onto the carcase from the weasand or a ruptured paunch. This will happen if the weasand is not plugged or tied properly. The paunch can rupture during the evisceration process. Carcase MHA monitors will find ingesta mainly on the forequarter but it can occur anywhere on the rest of the carcase. Urine Urine is considered a ZT in some plants. Urine can leak from pizzles onto the carcase or a bladder can be burst in the evisceration pro. Urine does not usually leave a stain on the carcase so it is impossible to see unless the operator identifies the area at the point of contamination. This is usually done with a coloured tag that tells the trimmer where to trim. Carcase MHA monitors will find urine contamination occurs mainly on the middle and forequarter of the carcase. Milk Milk spillage is considered a ZT and is controlled by removing the udder intact. Milk leaks from udders onto the carcase if the udder is not properly removed. Milk does not usually leave a stain on the carcase so it is impossible to see unless the MHA monitor finds a remnant of the udder on the carcase. This is usually regarded as evidence of milk contamination. Carcase monitors will find udder remnants in between the hind legs. Other physical contamination seen on skin on goat carcases Hair Those monitoring goat carcases will often see loose hairs that need to be trimmed. Likewise there maybe a group of attached hair that should have been shaved cleanly from the carcases. Scurf Scurf is shed skin and hair that can be found anywhere on the carcase and looks like a white powdery substance. Bristle Short black bristle is not considered contamination on a skin on goat carcase because: micro testing has shown that this bristle does not carry any additional micro contamination it is no different from the white bristle on a pig carcase

18 Training support materials for monitors performing carcase MHA on skin-on goats consumers do not object to the presence of short bristle on cuts of skin on goat. When the bristle occurs in skin folds it is difficult to remove without damaging the carcase. Pigmentation of goat skin Pigmentation or a colouring of skin occurs naturally on goats and is not a contaminant. Pigmentation occurs commonly and can be found on any part of the goat. The colouring is usually a grey or a light purple. Pigmented skin does not carry any more micro contamination than non-pigmented skin and does not need to be trimmed. How do monitors scan a carcase? When identifying defects on a skin on goat carcase MHA monitors use a systematic scanning method. The diagram below shows the scanning lines for goats recommended in the MHA manual. Categorisation of carcase defects Defects are classified to reflect the effect of the defect on the appearance or wholesomeness of the product into minor, major or critical categories. Carcase defect categories Defect Category Minor Description Affects appearance; not food safety 18 MINTRAC 2016

19 Training support materials for monitors performing carcase MHA on skin-on goats Major Critical Zero tolerance Has potential to affect food safety Seriously affects food safety Contamination with faeces, ingesta, milk and urine Classification of carcase defects Minor Major Critical Zero Tolerance Faeces, Ingesta, Milk, Any Amount 1 Bruises / Blood Clots Seed 2 (Not associated with inflammation) 2-5 cm (GD) >5 cm diam 2 or more majors >20 Rail Dust, Specks, Hide and Wool Dust 5-10 scattered specks scattered specks >20 scattered specks Smears and Stains (incl. Urine bile, oil and grease) Hide and Wool Strands 3 1 cm diam 1-2 cm diam >2 cm diam 5-10 strands strands >20 strands Hide and Wool Clusters and Hide, Scurf, Toe Nails 1 cluster of hair Hide <1 cm diam 2-3 clusters Hide 1-5 cm diam 3 clusters Hide >5 cm diam Foreign Objects and Extraneous Tissue 4 (includes parts of other organs and loose attached mucosa) Pathology 5 1 incidence 2 incidences 3 incidences Any incidence For a defect to be rated as zero tolerance it must be clearly identifiable to the naked eye as faeces, ingesta, milk. 1. Retained udder fragments are evidence of milk contamination.

20 Training support materials for monitors performing carcase MHA on skin-on goats 2. Short shaved bristles on skin on goats are exempt as hairs. 3. Gut segments including oesophagus are classified as zero tolerance. 4. Vaccination scars are classified as foreign tissue, abscesses as pathology. Defect ratings Target defect ratings for goats not receiving a pre-evisceration wash. Skin on Goats 1.0 Level of macro-contamination Acceptable Marginal > 1.5 Unacceptable An average defect rating for each species processed in a shift (average of all lots) should be calculated to establish overall trends in dressing performance at the establishment and should be plotted in line graph form. It is this average defect rating which should be considered when adjusting the level of sampling for carcases and carcases to normal, intensified or reduced. Recording defects Defects are recorded in the appropriate column (minor, major, critical or zero tolerance) on a carcase defect recording sheet. Examples of suitable recording forms are illustrated in Appendices 11 and 12 of the Department of Agriculture s publication Meat Hygiene Assessment (Second Edition). Forms with a different layout can be employed provided they retain the concept and record at least all of the same data. Carcase assessment recording shall: record the assessment of samples in the appropriate columns on the recording sheet record the assessment of multiple carcases in each column note the number of samples recorded at the top of each column where carcases or carcases are divide into sections for assessment, all defects from the sections that make up one carcase or side must be added together to determined how the defect is scored for that carcase non-scoring defects for carcases and carcases are not cumulative. 20 MINTRAC 2016

21 Training support materials for monitors performing carcase MHA on skin-on goats Corrective action-carcases General Corrective action must address both immediate and the longer term prevention of recurrence measures. Corrective action shall be approached on the basis of: immediate corrective action required with unacceptable and marginal product and zero tolerance findings establishing trends and adjusting unacceptable operations identifying repetitive and serious deficiencies and implementing corrective action to eliminate or reduce their occurrence (prevention of recurrence). For any zero tolerance Detection identified during product monitoring the corrective action must be implemented as per the written work instruction (see Australian Government- Agriculture Meat Notice 2000/04). This instruction must cover the product involved (the individual item and the lot in which it occurred) and the process that produced it. The corrective action must be recorded and the effectiveness of the action verified and recorded. An example of the type of record required is in Attachment 2. Existing monitoring sheets could also be used as long as the record is comprehensive. Immediate corrective action - carcase All defects detected during monitoring shall be trimmed immediately. It is useful to keep the trimmed defects to help identify the areas where the process failed. This may allow the corrective action to be better targeted. One recording of a zero tolerance defect in a monitoring sample from a lot, shall subject the entire lot to the same corrective action as an unacceptable lot regardless of the overall defect rating. Corrective action for carcase lots recording marginal or unacceptable defect ratings shall be conducted in accordance with the appropriate option in the following table.

22 Training support materials for monitors performing carcase MHA on skin-on goats Corrective action for carcases Categorisation of macrocontamination (defect rating) for a lot Corrective action Marginal First score Two successive scores (second on reassessment) Repeat the assessment or treat as unacceptable (as elected by the company) Treat as unacceptable Unacceptable First Score Impose an additional trim on all product in the lot - this trim is in additional and prior to pre-boning trim, load out, pre-bagging or pre-carton trim of quarters, carcases or carcases, or Two successive marginal scores (Second on reassessment) or or Where product is boned on the same establishment, intensify the pre-boning trim by placing special emphasis on identified problem areas, according to the established program agreed between the company and Australian Government- Agriculture. One or more zero tolerances. The effectiveness of this trim must be verified by sampling and the results of this recorded. There must be feedback to correct the process which created the defects and there must be a record of this. Zero tolerance and carcases Where a zero tolerance defect is detected in a monitoring sample, the lot is rated unacceptable; Figure 3 provides two options for the application of corrective action to the affected lot. Where the option of an intensified pre-boning trim is adopted, it should be tailored to the particular problem area/s and the degree of the problem. 22 MINTRAC 2016

23 Training support materials for monitors performing carcase MHA on skin-on goats As an example, where zero tolerance defects are periodically detected on hocks to a minor extent, the lot can be targeted for special attention to this area of the carcase at pre-trim - clearly where there is no contamination visible, there is nothing to remove. Where zero tolerance is identified, part of the corrective action should include attention to the problem area by the operators responsible for tasks associated with the defect occurrence and slaughter floor trimmers. The principles relating to corrective action for zero tolerance apply equally to load out. CCP monitoring and MHA Meat Notice Amended performance criteria for the assessment of the effectiveness of sheep/lamb and goat slaughter floor process control (HACCP) was issued by the Department with the purpose of amending the performance criteria relating to the ongoing assessment of the effectiveness of process control on small stock slaughter floors. Under this meat order monitoring for the CCP on the slaughter floor after the final trim will require the following sampling regime Monitoring frequency for carcases at the slaughter floor CCP Total number of carcases in the lot Minimum number of units* to be monitored Number detections to breach CCP > Any detection of zero tolerance defects in a sample is a breach of the CCP and must be dealt with in accordance with the Approved Arrangement. This monitoring for ZTs at the slaughter floor CCP can be combined with the gathering of MHA data to avoid duplication of activity. It may be the case that the number of carcases subjected to MHA is less than the number examined as part of CCP monitoring in which case the extra carcases need only to be examined for zero tolerance (ZT) defects. The maximum number of detections in a moving window of 1000 units sampled is 10. If this number of detections is exceeded then a reassessment of the HACCP plan by the processor will be required. The reassessed HACCP plan will be submitted to the department for re-approval. Once approved, the window will be reset. Ongoing breaches of the window (i.e. failures of preventive action) will adversely impact audit outcomes and may lead to further sanctions and market delisting.

24 Training support materials for monitors performing carcase MHA on skin-on goats Bibliography These publications were used to develop this training material. Agriculture and Resource Management Council of Australia and New Zealand, AS 4696:2007 Australian Standard for the hygienic production and transportation of meat and meat products for human consumption, CSIRO publishing, Collingwood, Vic. MINTRAC 2011 Meat Hygiene Assessment Kit (3rd Ed) Meat Notice and enhanced ZT monitoring for export registered sheep, lamb and goat processing plants Meat Notice Amended performance criteria for the assessment of the effectiveness of sheep/lamb and goat slaughter floor process control (HACCP) Additional resources Registered Training Organisations (RTOs) should refer to the Unit-by-Unit listing of resources on the MINTRAC website for additional resources to support the delivery of this Unit. RTOs which develop or identify additional resources are encouraged to advise MINTRAC so that these can also be added to the Unit-by-Unit listing. 24 MINTRAC 2016

25 Assessment materials for AMPA3072 Perform carcase Meat Hygiene Assessment Assessment materials for Error! No text of specified style in document. Error! No text of specified style in document. Assessment tools The following assessment tools can be used when they have been customised to incorporate the plants work instructions, SOPs and documentation. They are designed to be used by RTOs delivering the accredited Unit AMPA3072 Perform carcase Meat Hygiene Assessment. They can also be utilised by companies that are conducting inhose training for those performing carcase MHA monitoring. Below is the mapping of the assessment tools against the elements and performance criteria of the Unit Evidence guide Trainee: Assessor: Company/workplace: Registered Training Organisation: AMPA3072 Perform carcase Meat Hygiene Assessment Workplace referee s report Test or quiz On-the-job assessment with assessor observation Elements and performance criteria Element 1: Monitor carcase product

26 Training support materials for monitors performing carcase MHA on skin-on goats Select samples for assessment according to the approved sampling plan for sample size and frequency. 1.1 Conduct assessment utilising appropriate facilities, lighting and time. 1.2 Monitor products for defects according to the agreed criteria and classification. 1.3 Scan carcases using the approved scanning lines. 1.4 Record defects accurately using the correct forms or electronic system. 1.5 Implement immediate corrective action according to the Meat Hygiene Assessment (MHA) program's requirements. 1.6 Monitor carcases according to the workplace requirements for hygiene and sanitation, and workplace health and safety. 1.7 Assessment requirements Performance evidence Candidates must demonstrate ability to: instigate corrective actions when appropriate AR1 monitor product for defects according to the MHA program AR2 calculate defect ratings AR3 record the monitoring results accurately AR4 apply relevant communication skills AR5 apply relevant regulatory and workplace requirements AR7 Knowledge evidence Candidates must demonstrate knowledge of: how carcase monitoring is to be undertaken AR9 how defect ratings are detected AR10 hygiene and sanitation requirements when monitoring product AR11 26 MINTRAC 2016

27 Assessment materials for AMPA3072 Perform carcase Meat Hygiene Assessment workplace health and safety requirements when monitoring product AR12 types of defects to be identified on carcase product AR13 when and how corrective actions are to be taken in response to monitoring outcomes AR14 how the approved sample plan is implemented for product monitoring AR15 classification of defects AR16 purpose of an MHA program AR17 relevant regulatory and workplace requirements. AR18

28 Assessment materials for AMPA3072 Perform carcase Meat Hygiene Assessment Workplace referee's report Trainee: Assessor: Company/workplace: AMPA3072 Perform carcase Meat Hygiene Assessment Instructions to the Workplace Referee The Workplace Referee is an experienced supervisor or colleague of the trainee who is able to provide evidence about: the trainee s ability to carry out the tasks described in the Unit of Competency at the speed and to the level of proficiency expected in the workplace consistency of performance over time application of the Employability Skills, as described under Required Skills and Knowledge. The Workplace Referee s Report forms an essential part of the overall assessment of the Unit, and should only be completed and signed when the Workplace Referee is confident that competency has been achieved. The Workplace Referee is encouraged to record notes and observations related to the assessment onto the recording sheet. Information about the Workplace Referee (please print clearly) Name Job title Contact number Period of time when Trainee was observed by Workplace Referee Evidence: Does the trainee consistently: follow each step in the work instruction for MHA carcase assessment, including: Map to E&PC Referee s comments: 28 MINTRAC 2016

29 Assessment materials for AMPA3072 Perform carcase Meat Hygiene Assessment sample selection according to specified sample size and frequency use of appropriate facilities for assessment monitoring for defects according to agreed criteria and classifications scanning using appropriate scanning lines accurate recording of data implementation of immediate corrective action where required? maintain pace with speed of production? scan carcase effectively? AR6 AR2 1.4 identify contamination? 1.3 AR2 trim contamination? work safely? work hygienically? instigate corrective actions when appropriate? dispose of trimmings correctly? document assessment according to MHA, SOP? record the corrective and preventive action taken? forward data to QA Manager according to workplace SOP? prepare, store and use knife appropriately (where required as part of the MHA procedure): sharpen? sterilise? handling safely? AR1 1.6 AR12 AR11 AR1 AR1 1.5 AR4 1.5 AR4 1.5 AR4 AR18

30 Assessment materials for AMPA3072 Perform carcase Meat Hygiene Assessment techniques? follow workplace WHS procedures including: workplace policies and procedures? PPE? manual handling? knife handling? follow hygiene and sanitation procedures including: personal hygiene SOP? work instruction? sterilising equipment correctly? washing hands properly as required? maintain, clean and store personal equipment properly including: knife and kit? aprons? uniforms? boots? bump cap or hard hat? maintain and use a sharp knife? apply relevant communication skills? calculate defect ratings accurately? record the monitoring results accurately? identify and apply relevant regulatory and workplace requirements? monitor product for defects according to the MHA program? AR12 AR11 AR18 AR18 AR5 AR3 AR4 AR7 AR2 Referee comment and signature: Date: Trainee comment and signature: Date: 30 MINTRAC 2016

31 Assessment materials for AMPA3072 Perform carcase Meat Hygiene Assessment Assessor comment and signature: Date:

32 Assessment materials for AMPA3072 Perform carcase Meat Hygiene Assessment Test or quiz Trainee: Assessor: Company/workplace: Registered Training Organisation: AMPA3072 Perform carcase Meat Hygiene Assessment Information for assessors The test or quiz can be conducted as either a written or oral assessment depending on the Unit requirements, and context and capability of the trainee. This sheet should never be provided to the trainee. Assessors should use the questions to make up their own test instruments. The sample questions need not be used for a single test see the customisation suggestions earlier in this document for suggestions on how to modify the test. Assessment requirements This quiz is designed to assess the participant s understanding of the correct procedures for completing a carcase monitoring form. Sample questions carcases recorded the following defects on the slaughter floor following the wash: six carcases each carrying four strands of loose hair, three carcases each carrying one cluster of attached hair, two carcases each with bruising 8 cm diameter, one carcases with an abscess, three carcases each showing bile stains 1 cm diameter, one carcases showing grease stains 2 cm diameter, two carcases each with one piece of retained liver 3 cm diameter. Map to Assessment Requirements AR3 AR4 32 MINTRAC 2016

33 Assessment materials for AMPA3072 Perform carcase Meat Hygiene Assessment Complete the following (next page) Carcase Defect Recording Form, Calculate the Defect Rating, Indicate whether the lot is acceptable, marginal or unacceptable. 2. This question is designed to assess the participants understanding of the correct procedures for completing a Zero Tolerance Detection Report 1.5 AR4 A zero tolerance defect is found on the rim of the topside at the MHA check on the slaughter floor. Complete the Zero Tolerance Detection Report. Lot Identification - Time Found - Monitoring Point - Defect - Corrective Action: Lot - Side - Process Verification Slaughter Floor Monitor Slaughter Floor Supervisor

34 Assessment materials for AMPA3072 Perform carcase Meat Hygiene Assessment Corrective Action (Rework) Location - Process - Verification - Boning Room Monitor Boning Room Supervisor 3. List and explain the key steps in carcase process monitoring. AR9 4. Explain how defect ratings are calculated. AR10 5. What are the hygiene and sanitation requirements when monitoring carcases? AR11 6. What are the WHS requirements when monitoring carcases? AR12 7. Describe the types of defects to be identified on carcase. AR13 8. Explain when and how corrective actions are to be taken in response to monitoring outcomes. 9. Explain the requirements of the approved sample plan for carcase monitoring in your workplace. AR14 AR How do you classify defects? AR What is the purpose of an MHA program? AR What regulatory requirements apply to carcase MHA? AR18 34 MINTRAC 2016

35 Assessment materials for AMPA3072 Perform carcase Meat Hygiene Assessment Carcase Defect Recording Sheet Date... Assessor... Establishment... Ovine Bovine Equine Porcine Vealer Domestic Feedlot Feral earling Other... Sucker lamb Daggy Older lamb Dirty/Wet Sheep Seedy Porker Baconer Back-Fatter Other Species...Number in Lot... Defect (1) Faeces, Milk Ingesta, Urine Score Zero Tolerance Any (2) Strands - Minor (5-10) Hair, Major (11-20) Wool, Critical (> 20) (3) Clusters - Minor (1) Hair, Major (2-3) 1 to 5 6 to 10 Number of Samples... Side/Carcase (Up to 5 per Column) to to to to to to to to 50 Sub Totals Mi Ma Cr ZT

36 Assessment materials for AMPA3072 Perform carcase Meat Hygiene Assessment Wool, Critical (> 3) (4) Bruises, Minor (2-5 cm diam) Clots, Major (> 5 cm diam) Offal Pieces Critical ( 2 majors) (5) Hide, Minor (< 1 cm) Scurf, Major (1-5cm) Toe-nails Critical (> 5 cm) (6) Pathology Critical Any (7)Smears, Minor ( 1 cm diam) Stains Major (> 1 cm diam) (includes bile) Critical(> 2cm diam) (8) Specks, Rail Minor (5-10) Dust, Hide & Major (11-20) Wool Fallout Critical (> 20) (9) Minor(5-10) Seed Major (11-20) Critical (> 20) (10) Foreign Minor 1 incidence Objects/ Tissue Major 2 incidences Critical 3 incidences Total 36 MINTRAC 2016

37 Assessment materials for AMPA3072 Perform carcase Meat Hygiene Assessment Minor x 1 Defect Major x 3 Scores Critical x 6 Total Defect Score Zero Tolerance x 10 Comments: Defect Rating = = Acceptable Marginal Unacceptable

38 Assessment materials for AMPA3072 Perform carcase Meat Hygiene Assessment 38 MINTRAC 2016

39 Assessment materials for AMPA3072 Perform carcase Meat Hygiene Assessment Answer sheet (for assessor use only) Note: the suggested answers are provided as a guide only. It is not mandatory that every aspect of the suggested answer be covered by the trainee and the assessor should use their own judgement to determine whether the question has been sufficiently and accurately answered. Remember also, that trainees may propose answers that are different to what has been suggested here again these should be considered on merit. No Question Suggested answer beef carcasesrecorded the following defects on the slaughter floor following the wash: six carcases each carrying four strands of hair, three carcases each carrying one cluster of hair, two carcases each with bruising 8 cm diameter, one carcaseswith an abscess, three carcases each showing bile stains 1 cm diameter, one carcasesshowing grease stains 2 cm diameter, two carcases each carrying pieces of hide 2 cm diameter, two carcases each with one piece of retained liver 3 cm diameter. Complete the following (next page) Carcase Defect Recording Form, Calculate the Defect Rating, Indicate whether the lot is acceptable, marginal or unacceptable. 2. This question is designed to assess the participants understanding of the correct procedures for completing a Zero Tolerance Detection Report 3. List and explain the key steps in carcase process monitoring. 4. Explain how defect ratings are calculated. No sample answer provided No sample answer provided Refer work instruction See course notes

40 Assessment materials for AMPA3072 Perform carcase Meat Hygiene Assessment 5. What are the hygiene and sanitation requirements when monitoring carcases? 6. What are the WHS requirements when monitoring carcases? 7. Describe the types of defects to be identified on carcase. 8. Explain when and how corrective actions are to be taken in response to monitoring outcomes. 9. Explain the requirements of the approved sample plan for carcase monitoring in your workplace. Refer work instruction Refer work instruction Refer course notes Refer course notes Refer work instruction 10. How do you classify defects? Refer course notes 11. What is the purpose of an MHA program? 12. What regulatory requirements apply to carcase MHA? Refer course notes Refer course notes 40 MINTRAC 2016