continuous improvement for argentine dairy … · technical assistance to small and medium...

CONTINUOUS IMPROVEMENT FOR ARGENTINE DAIRY LABORATORIES THROUGH REDELAC

National Institute of Industrial Technology, INTI. National Institute of Industrial Technology, INTI. Dairy Industry Technological Research Centre. INTI LACTEOS. BuenDairy Industry Technological Research Centre. INTI LACTEOS. Buenos Aires.os Aires. Argentina.Argentina.

Roberto CastaRoberto Castaññedaeda

ICAR 37th Annual Meeting – Riga, Latvia (31 May - 4 June, 2010)

DairyDairy Sector in ArgentinaSector in Argentina

2

The argentine dairy complex is an important and dynamic food chain of the argentine economy, because of

the extension and distribution in the territory.

the generation of employment.

and the promotion of regional economies , where big, medium and small enterprises (milk producers and dairy industries) coexist.


MilkMilkProductionProduction

Milk production in Argentina: 10 billion liters.11º place in the ranking of milk world producers.2nd place in Latin America.2.3 million dairy cows. Most of them “holando argentina” breed (holstein).95 % of the milk produced belongs to the “Pampeana”Region (800.000 km 2)11.000 dairy farms

Argentina produce also goat, ewe and buffalo milk.


Titulo: Arial 32

Argentina – China Food Scienceand Technology Centre

Workshop on Plant and Animal Protein

Buenos Aires, -10-14 May, 2010

3er Congreso Internacional de Lechería Colonia

4ICAR 37th Annual Meeting – Riga, Latvia (31 May - 4 June, 2010)

Dairy Industry.Dairy Industry.

Important rol in the food and beverage sector.

More than 900 dairies of different sizes (9%).Different technologies, from high technology to artisanal equipment. 29.000 employees (10%) work in the dairy sectorTotal income: u$s 3.400 million dollars (13%)Milk destination: cheese (45%), milk powder (24%), fluid milk (19%), others.All dairy products are produced. Exports (2007: 240.000 ton / u$s 715 millions)


Buenos Aires, -10-14 May, 2010

3er Congreso Internacional de Lechería Colonia

6ICAR 37th Annual Meeting – Riga, Latvia (31 May - 4 June, 2010)

Laboratories for milk Laboratories for milk quality, physicochemical quality, physicochemical testing, microbiology, testing, microbiology, residues and contaminants, residues and contaminants, sensory evaluation, and sensory evaluation, and othersothers..

INTI LINTI LáácteoscteosDairy Industry Technological Dairy Industry Technological Research CenterResearch Center

2 work places (Buenos 2 work places (Buenos Aires and RafaelaAires and Rafaela))

92 professionals and 92 professionals and technicianstechnicians



Research and development (new products)Research and development (new products)

Technical assistance to small and medium enterprises Technical assistance to small and medium enterprises (technology, GMP, HACCP; ISO 22.000, (technology, GMP, HACCP; ISO 22.000, eccecc) )

Training courses.Training courses.

Quality assurance to laboratories.Quality assurance to laboratories.

THE REDELAC IS A COMPLETE INTEGRATED SYSTEM:

THE REDELAC THE REDELAC IS A COMPLETE INTEGRATED IS A COMPLETE INTEGRATED SYSTEM: SYSTEM:

Dairy National Reference Laboratory

Dairy National Dairy National Reference LaboratoryReference Laboratory

The first accredited proficiency testingprovider ISO 17043 in Latin AmericaThe first accredited proficiency testingThe first accredited proficiency testingprovider ISO 17043 in Latin Americaprovider ISO 17043 in Latin America

SICECAL, The ArgentineCentralized Calibration System

SICECAL, The ArgentineSICECAL, The ArgentineCentralized Calibration SystemCentralized Calibration System

Technical AssistanceTechnical AssistanceTechnical Assistance



Centralized calibration.Centralized calibration.

Control of performance of laboratories.Control of performance of laboratories.

Evaluation of results.Evaluation of results.

2009: Is focused on “continuous improvement of milk laboratories”

Proficiency Testing programmes related to raw milk quality:

Monthly raw milk ControlMonthly raw milk ControlInstrumental equipment ControlInstrumental equipment Control

Technical AssistanceTechnical Assistance


Analyses under “Monthly Raw Milk Control are:

- Fat content- Total protein- Total solids- Lactose- Ash- Presence of antibiotics- Freezing point- Enumeration of somatic cells- Enumeration of microorganisms at 30ºC


1. Survey of PT participants

2. Definition of indicators and quality tools

3. Segmentation

4. Determination of technical assistance required

5. Planning of annual work and proposal of aims


6. Technical Assistance

To improve the To improve the performance of performance of dairy dairy laboratorieslaboratories

1. Survey of PT participants


Laboratories´s geographicallocation



deviation from a requirementdeviation from a requirement

unsatisfactory results of a proficiency testing roundunsatisfactory results of a proficiency testing round

evaluate as nonconforming work (NC).evaluate as nonconforming work (NC).


INDEX

1 ratio NC / total tests

2 ratio NC / total participant laboratories

3 ratio NC / each parameters




Final reports of each round, where the historical performance for each parameter is includedMonthly table of NC of all laboratoriesAnnual table of NC of each laboratoryMonthly graphic of NC of all the parametersAnnual graphic of NC of each parameterAnnual graphic of Index 1 for each laboratoryIshikawa diagrams for each parameterCheck lists of each parameter

QUALITY TOOLS


2. Definition of indicatorsand quality tools

Monthly raw milk control.Monthly raw milk control. Instrumental equipment controlInstrumental equipment control..


Monthly table of NC of all laboratories( July 2009)

011111111

8I

00H

01

1G

01111111

7F

2111111111

7E

111

1D

3111111111111

9C

1111111111

8B

00A

NC DIEM

30ºCESCFPALTSTPFCtests NºLaboratory

nameRegistration

NºITEM

%NC

Total tests

NC DIEM 30ºCESCFPALTSTPFC

9,80,025,05,99,10,00,00,022,211,8

12041100042

Total1416171169151817123

Indice 1 = NC / N° de ensayos totales: 0,10Indice 2 = NC/ N° total de laboratorios : 0,57

FC:Fat Content – TP: Total Protein - TS:Total solid – L:lactose – A:ash – FP: Freezing Point – ESC:Enumeration of somatic cells – EM 30ºC: Enumeration de

microorganisms 30ºC – DI: Detection of inhibitors.

Annual table of NonConformities - Laboratory X

Index 1 = NC/Nº total tests: 0,05

5,412,525,0%3000000012

888080888560

11111117Sept

01111111

7Ag

01111111

7July

01111111

7June

2111111111

7May

01111111

7Apr

00March

01111111

7Feb

111111111

7January

NC / monthDIEM 30ºC

ESCFPALTSTPFCtestN°Month



Monthly graphic of NC (for all parameters)

%NC for parameter - December 2009(total: 23 labs.)

17,6%

11,8%

6,7%

0,0% 0,0%

27,3%

16,7%

21,1%

14,3%

0,0%5,0%

10,0%15,0%20,0%

25,0%30,0%

FC

Prot

ein

Sol

ids

Lact

ose

Ash

F P

oint

Som

atic

cells M

O30

ºC

Inhi

b

Parameters

%N

C

Annual graphic of NC (for each parameter)

%NC Fat content - 2009(total: 17 labs.)

35,3% 33,3%

12,5% 12,5%

41,2%

23,5%

11,8%

29,4%

11,8%

0,0%

11,8%17,6%

0,0%5,0%

10,0%15,0%

20,0%25,0%30,0%35,0%40,0%45,0%



ConcentraciónLibre de N

Vencimiento

Contenido de N

Grado analítico reconocido

Destilada o pureza equivalente

Ensayo en blanco

No conformidad

Recepción y Almacenamiento

Determinación

Temperatura

T recepción

Conservantes Exposición a condiciones adversas

T almacenamiento

Estado

Acido sulfúrico

Vencimiento

Acido clorhídrico

Concentración

Digestión

Ácido sulfúrico debe hervir

TemperaturaPeso muestra

Tiempo

Titulación

Destilación

TemperaturaEspuma

Aspecto digerido

Lecturas

Sol. de NaOH

Sacarosa

Velocidad succón scrubber

Test de recuperados

N

Temperatura de precalentamiento

Agua

Concentración

Limpieza

Libre de NVencimiento

Reactivos

Equipos

Calibración

Mantenimiento

Personal

Competencia

Calificación

Punto final Bureta

Ishikawa diagram: determination of total protein



Designed check lists are available as self-control tool


3. Segmentation

Using Index 1: ratio NC / total tests

GROUP INDEX 1 (VALUE)1 0,00 – 0,10

2 0,10 – 0,20

3 0,21 – 0,25

4 > 0,25

SIGALEC 0,08 – 0,12 *

* Values found at the moment of survey

4. Determination of technicalassistance required

5 defined groups


5. Planning of annual work and proposal of aims

quantity of laboratories

Group Value index 1 dec 08 aim- dec 09

SIGALEC 0,08 - 0,12 4 4

1 0,00 - 0,10 7 7

2 0,11 - 0,20 3 5

3 0,21 -0,25 3 6

4 >0,25 5 0


6. Technical Assistance (TA)

NC detected?

Round results

Trenddetected?

Corrective/ Preventive recommendations

System alert

effective actions?

Punctual TA required

Communication with laboratory

Monitoring following rounds

Indicators and quality tools

yes

yes

no

no

no

Continuous monitoringof laboratory performance

yes


Results and discussion

Less number of labs. with value of index NLess number of labs. with value of index Nºº1 > 0,211 > 0,21

Some laboratories improve performance Some laboratories improve performance since the system implementationsince the system implementation

Nº NC/ Nº total tests - 2009

0,190,17

0,15

0,13

0,22

0,12

0,100,12

0,19

0,13

0,08

0,14

0,00

0,05

0,10

0,15

0,20

0,25

ener

o

febr

ero

mar

zo

abril

may

o

juni

o

julio

agos

to

sept

iem

bre

octu

bre

novi

embr

e

dici

embr

e

Tendency to decrease NC / total testsTendency to decrease NC / total tests



Annual graphic of NC (for each parameter)

%NC Fat content - 2009(total: 17 labs.)

35,3% 33,3%

12,5% 12,5%

41,2%

23,5%

11,8%

29,4%

11,8%

0,0%

11,8%17,6%

0,0%5,0%

10,0%15,0%

20,0%25,0%30,0%35,0%40,0%45,0%

Decrease of %NC in the parameters with highest value at the starting point

Monthly monitoring raw milk2009

(total: 23 labs.)

79,8%74,6%

84,9% 86,0%92,9%

86,2% 86,3% 91,2% 94,4%

20,2%25,4%

15,1% 14,0%7,1%

13,8% 13,7% 8,8% 5,6%

0%10%20%30%40%50%60%70%80%90%

100%

Fat C

onte

nt

Prot

eins

Solid

s

Lact

ose

Ash

Free

zing

poin

t

Som

atic

cells

MO

30º

C DI

%conformities %NC

Indentification of tests which require more attention



ALARM SYSTEM

CONTINUOUS IMPROVEMENTFOR DAIRY LABS

INTEGRATED SYSTEM REDELAC-SICECAL

consolidation

implementation

National Institute of Industrial Technology, INTI. National Institute of Industrial Technology, INTI. Dairy Industry Technological Research Centre. INTI LACTEOS. BuenDairy Industry Technological Research Centre. INTI LACTEOS. Buenos Aires. os Aires. Argentina.Argentina.

[email protected]

continuous improvement for argentine dairy … · technical assistance to small and medium...

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