DSM Food Specialties - SafeFood360
Johan Noordover
January 14, 2016
Case Study - Holistic project, people, process & system
nutrition health materialsactive in:
We create solutions to bring healthier, better
performing and more sustainable products to
the lives of people today and for generations
to come.
DSM Life Sciences and Material Sciences company
Sales~€10 billion
Global presence~25,000 employees
At Euronext NYSE
Sustainability leader Top ranking Dow Jones
Sustainability Index
Enzymes
Cultures
Savory flavors
Hydrocolloids
Preservation
systems
Vitamins
Nutritional lipids
(Omega 3 & 6)
Carotenoids
Health
ingredients
INDUSTRIAL BIOTECH(21st century)
CLASSICAL BIOTECH (19th century - 1869)
MODERN BIOTECH(20th century)
Yeast — over a century of experienceRoyal Dutch Yeast and Alcohol factory since 1869
• Today DSM produces a variety of ingredients produced from yeast:
– Yeast extract
– Enzymes such as lactase, pectinase, invertase
– Caratenoids
DSM Food Specialties today
• Leading positions in food & beverage enzymes, cultures and yeast extracts
• Over 1500 employees worldwide
• Manufacturing locations in Europe, North & South Americas, Asia, Australia
• Food Innovation Center with dedicated application and sensory specialists
• Regional application labs in China, the Netherlands, USA
DSM ingredients support key trends
DSM in Dairy
• One of the broadest portfolios of coagulants and other enzymes, cultures,
probiotics, preservation systems & antibiotic residue tests
• Global leader in lactase solutions
• Acquisition Cargill Cultures & Enzymes in 2013 – global manufacturing
footprint, application support and R&D
DSM Enzymes help to do more with less
Baking
Brewing
Oils & Fats
Fruit processing
Grain processing
• Reduce production costs
• Get more out of raw materials
• Improve appearance, taste & mouth feel
• Replace undesired substances like acrylamide
• Create healthier products
• Keep products fresh for longer
• Leading supplier of yeast extract based
taste components to the culinary industry
• Natural solutions for every taste direction
• Building taste: unique block-by-block
approach
DSM in Savory
DSM’s Natural food preservativesProtection you can trust
CheeseFermented
milk products
Meat Beverages Baking
• Natural anti-microbial, anti-mold and yeast protection
• Improved shelf life and product safety
• No effect on taste, color or smell
• Providing full control over production processes
• Natural preservatives
• High quality products, safe from toxins or harmful contaminants
Our commitment: Quality for Life™
As a pioneer and market leader, DSM
Always gives you the very best ingredients, with the
highest quality level
Is the most reliable company that sets global
standards and ensures product safety
Can always trace the origins of any
ingredients, wherever manufactured or
sourced
Example Quality for Life
DFS Quality Policy – Our Vision
We deliver superior quality, safe products and excellent services
that add value and help our customers to grow and secure
their business
We help our customers to make consumers choose their products thanks to our added value high
quality ingredients and processes
We are responsible Corporate Citizen, with the highest social,
ethical and environmental standards in our industry
We develop and maintain long-term trustful and sustainable
partnerships with our suppliers to our mutual benefit
We offer innovative products, processes, concepts and
solutions that improve the quality of life
We are a preferred employer offering a safe working
environment that values individual and group
performances
In all our markets, we are a reliable and competent
industrial partner that complies with the local rules and
regulations
We are a benchmark for our competitors when it comes to
quality.
First
choice
for
13
DFS Quality Strategy
Sit
e
Infr
ast
ructu
re*
Perf
orm
ance &
Impro
vem
ent
Cert
ific
ati
on &
Regula
tory
Com
pliance
Sta
ndard
izati
on /
Harm
oniz
ati
on
Data
& D
ocum
ent
Managem
ent
Cust
om
er
Excellence
People
, O
rganiz
ati
on
&
Com
munic
ati
on
Flawless Execution
Rationale for SafeFood360
• DSM Food Specialties implemented SF360 :
– SF360 is a Food Safety Management System that
supports the Quality vision of DFS.
– Integral Business Group Food Safety management to
get more oversight on BG and BU level
– Raise the bar for quality and food safety
– Efficiency by standardization and harmonization, also
for future changes
– Support the drive for legal and customer compliance
• SafeFood360 implementation (1 year)
– Quality and food safety project (not IT tool project)
– 11 manufacturing sites – harmonization
– BG level processes
14
SafeFood360 DFS status
• Implemented on all manufacturing sites
– Harmonized approach for some key processes
– As-Is situation for others, site specific
• DFS customer feedback:
– Impressed on speed and scope of the implementation
– Recognized as best in class system and would like to have it
as well
• Strong starting point for further harmonization
• Benefits will already materialize during FSMA implementation:
– DFS can absorb this in running business due to SafeFood360
implementation
Safefood360 maturity curve for DFS
HACCP, Deviations, Supplier Management
CAPA, Non-conformances, MOCB
Environmental monitoring, MOCM,
Pest Control, Glass Policy, Int. Audits
External audits,
Performance mgt.,
Customer logon
HACCP
• Group wide standardisation of HACCP
– Standard risk assessment and decision model
– Convert and translating existing HACCP studies of manufacturing sites
(around 30)
• Benefits:
– BG oversight of HACCP plans as basis for improvements
– Integration with new requirements (FSMA changes)
Deviation process is standardized
• Three types of deviations:
– CCP / oPRP “breaches”
– Process deviations
– Incidents
• Facts and figures captured in monitoring
module
• Potentially non-conforming products managed
in NC module
• Related corrective actions are captured in CA
module
• Benefits:
– Reporting and monitoring
– Supports escalation to BU and BG
Quality management processes
• Internal auditing – standardized internal audit approach
• Management review – standardized agenda
• Alerts – standardized to drive also the escalation process
• BG level reporting – reporting is used to get overview of
all the sites.
• Benefits:
– Connection to the BG QA plans
– Integrated QA management and oversight of issues
Supplier Quality Management Process - Into SF360
• SQM is centrally managed at Business Group level with Business Unit
responsibilities.
• Supplier information is collected and managed using Supplier portals
(assessments, questionnaires and documents)
MOC2.0 processin BPM
• Management of Change process is
centrally driven by Business Units to
also implement changes at
manufacturing sites
• In SF360 a 'Business Process Module'
is used for management of MOC
process (via a work flow).
• Process is split in different ‘phases'
(= e.g. ‘Review MOCB’)
• In a phase you add 'actions’ and
'due dates‘ on top of the predefined
ones.
1. prepare Change
Basic info
2. Pre-MOC
3. Risk Assessment
4. Review MOCB
5. MOCB Hold
6. MOCM
7. MOCM Hold
8. Implementation
9. Finalize
0. Create MOC
2
1
3
2
Phase responsible:
1: champion 2: MOCBc 3: MOCMchair
1
DFS Quality vision
Compliance Harmonization Standardization Efficiency
Holistic project,
people, process
& system
NO IT project
Manufacturing
sites
BG level QA
processes
Food Safety
Management