Spreadsheet: 739323d1625648192-countif-with-subtotal-2021_-external-nc-database
Sheet: Database

EXTERNAL and IQA NON-CONFORMANCE DATABASE
Total NC |  | Open |  | % Closure
 |  | Closed
Month | Auditor | NC No. | Results | Nature of NC | Description of NC | Corrections | Responsible | Target Date | Root Cause | Corrective Action | Responsible | Target | Status | Close Out Date
February | MARS | NC1 | Minor | Document Control | The titration monitoring was not carried out every 2 hours interval as per Sulfite Monitoring Report (Form#D-DCN-FR-01-02-05). It was informed that the actual practice for titration is carried out every shift, the monitoring will increases to 2 hourly if there is a problem with the spraying proces. | Set frequency of monitoring at least  once per shift and revise D-DCN-FR-01-02-05 Sulfite Monitoring Report to remove indicated frequency of "every 2 hours" | AKFare | 2021-03-08 00:00:00 | Forms used was not updated to reflect actual frequency of monitoring sulfite in-line | Revised D-DCN-WI-03-02 Sulfite Treatment to include frequency of at least once per shift for in-line sulfite monitoring | AKFAre | 2021-03-08 00:00:00 | Open
February | MARS | NC2 | Minor | Supplier Performance | The supplier performance for year 2020 has yet to be conducted. It was informed that there was error in data retrieval and rectification is in progress. | Informed Netsuite team on error on data extraction | AANgni | 2021-01-29 00:00:00 | Wrong parameters were used in the generation of the report | Revision of report format to include item list | AANgni | 2021-02-01 00:00:00 | Open
February | MARS | NC3 | Minor | Training Material and RM Specification | The training / raw material specification for coconut suppliers shall include elements of good agricultural practices eg coconut source shall not be near mining / industrial / waste disposal area, pest management, personal hygiene, transportation of coconuts, eg contamination of chemicals / mineral oils during transportation and other relevant requirements. | Conducted review of training materials and supplier's information form | BREquirme | 2021-02-10 00:00:00 | The general requirements on coconut deliveries as stated in the corporate document (CS-ING-02) was not captured  in the profiling of suppliers altough it was included /discussed during the nuts quality orientation. | [NAME] Information form (D-NBY-FR-04) | BREquirme | 2021-02-10 00:00:00 | Open
February | MARS | NC4 | Minor | HACCP Verification | The HACCP Verification Activities were not defined for CCP 2 Metal Detector in HACCP Plan - Desiccated Coconut, Section 8.0 CCP/oPRP Documentation (Doc#D-QFS-HD-01, Rev. 21, Issue Date 19 Jul 2020). | Reviewed CCP verification activities applicable to CCP 2 Metal detection | FSTeam | 2021-02-26 00:00:00 | CCP verification activities was mentioned in the CCP ID Section 8.0 CCP/oPRP but details on the activity was not discussed in the document | Revision of HACCP Plan for DCN to include verification related activites | FSTeam | 2021-03-15 00:00:00 | Open
February | MARS | NC5 | Minor | HACCP Validation | HACCP Validation shows that existing blancher setting for Lines 1 and 2 was not able to achieve product temp of 200 degF and retention time of 7 minutes but minimal food safety risk based on micro challenge conducted. Temperature distribution, thermal mapping, and Micro challenge are to be re-validate in 2021.  Optical sorter validation was carried out during initial set-up however there was no significant difference in specks count reduction during monitoring. It is recommended to carry out re-validation of optical sorters to ensure capability and effectiveness of the control measure. | Reviewed HACCP Development Procedure and existing Validation records for basis of establishing CCP and revalidation schedules | FSTeam | 2021-02-26 00:00:00 | Turn over of information from old FS Team to existing FS Team did not include turn over of reference material for setting CCP limits | Revision of HACCP Development Procedure if ever there is a need to align requirement of CCP Revalidation every 5 years if a customer requires for such revalidation activity. | FSTeam | 2021-04-01 00:00:00 | Open
February | MARS | NC6 | Minor | Measures for Prevention of Cross Contamination | Positive air pressure in the clean room is checked on every shift. The checking method is by pulling the door to ensure there is positive pressure. The specification of differential air pressure in clean room shall be defined with a measurable checking method. | Asked qoutation for devices or services that can measure differential air pressure | MHOllanes | Q3 | The site did not consider quantifying differential air pressure inside DCN Dry Area | Included Differential air pressure in the External Work Environment Measurement monitoring for 2021 | CPEndang | Q3 | Open
February | MARS | NC7 | Minor | Process Capability | The E.coli specification <10 cfu/g require further review, the specification is stated in wordings "None Detected in 10 grams". There is no discrepancy in COA to Mars. | Reviewed CoA reported values against existing Finished Product specification | GJAvillo | 2021-02-04 00:00:00 | Different formats were used in the CoA | Changed CoA Reporting to "None detected" instead of "Negative". Retained indicating qualitative value of <10 cfu/g and <3.0 MPN/g for E. coli as basis for "Non detected" reading since these values are the LOD of the methods used.  Change was conducted last December 2020 | GJAvillo | 2020-12-01 00:00:00 | Closed
February | M&S | NC1 | Minor | Internal Audit | There is an annual internal audit schedule with 2020 audits phased due to [NAME] restrictions, however the schedule doesn't cover M&S Outcomes and Requirements and CCP's are not audited on a quarterly basis. In addition, audits follow BRC clauses and are system based rather than the factory operating systems. | Reviewed IQA Plan for 2021 to align with M&S requirement. | CAJawa | 2021-02-15 00:00:00 | Internal audit schedule was based on existing IQA procedure where audit frequency is determined by the number of findings raised from the previous year. | Revise HACCP Plan to indicate quarterly frequency of CCP Audit as part of the Verification Plan. Cascade changes to Food Safety Team. Target date: April 2021 | CAJawa | 2021-02-15 00:00:00 | Open
February | M&S | NC2 | Minor | GMP | There are cleaning instructions in place for equipment but these follow a generic cleaning process and dont define how to clean difficult to access areas or key inspection points. | Conducted review of existing procedure pertaining to cleaning | AKFAre | 2021-02-15 00:00:00 | Cleaning procedure was not reviewed and updated to align with needs of the personnel conducting the activity. | Provision of One-Point-Lesson (OPL) with photos of Equipment as guide for cleaning activity. Target Completion Q3 2021 | AKFAre | Q3 | Open
February | M&S | NC3 | Minor | Packaging Material | The blue liners supplied by Macondray Plastics have not been certified to comply with G4 physical parameters. | Coordinated with FG on further steps | SSDop | 2021-04-16 00:00:00 | G4 Requirements were not considered in the site's annual testing plan | FB to send packaging samples from supplier for testing | SSDop |  | Open
February | M&S | NC4 | Minor | Water Risk Assessment | A water risk assessment has been documented to detail water usage and chlorination on site but it does not include details of the water distribution systems. | Conducted Water mapping of the Plant Water distribution system | ESErapio | 2021-02-11 00:00:00 | No established water distribution system from source to point of use | Established detailed water distribution mapping from source up to the point of use | ESErapio | 2021-02-11 00:00:00 | Closed
February | M&S | NC5 | Minor | Chemical Validation | There are data sheets for chemicals used on site which are appropriate for the task required but concentration checks are not conducted. | Reviewed existing Master Cleaning program validation even from Emerald and Sapphire plants | GCLorenzana | 2021-02-15 00:00:00 | Verification is being implemented. However, concentration checks of detergent soap was not considered. | Created procedure for Chemical Validation. Established Valdiation plan for Cleaning chemicals used and Conduct of validation. | GCLorenzana Cgabutero | 2021-03-30 00:00:00 | Closed
February | M&S | NC6 | Minor | Bulk Metal Detector Verification | Product passes through a bulk metal detector with rejected product removed by a pneumatic operated pusher, however although the detector alarms, a failsafe check of air fail is not conducted. | Checked the equipment for any response if air supply is compromised. Result show that the equipment would alarm if air supply is compromised | JCAlipes GZUlueta |  | Pneumatic check was not considered in the verification activity | Installation of valve to simulate "air supply failure" as part of daily verification. Target completion Q2 2021 | GZUlueta | Q2 | Closed
March | ISO 9001 | NC1 | Minor | Document Control | Process of document control has not been maintained appropriately | Reviewed Document masterlist for any obsolete or unupdated documents. Met with Local Document controllers for the estbalishment of cascading system for internal documents | CAJawa |  | 1. Cascading of updated documents were not able to capture all updated documents especially electronic copies of Procedures, Work Instructions, etc. 2. Document control for frequently updating document only considered the doc code and not the updating frequency of the document. | Revision of the Document Control Procedure to include section on how to treat frequently updating documents | CJawa | 2021-04-14 00:00:00 | Closed
March | ISO 9001 | NC2 | Minor | Control of production and service provision | Some of the important control messures have not been sufficietly defined under Control of production for Aseptic coconut water – Retail Process | Reviewed Assessment of the Bactofiltration step in Aseptic CW Retail process | Ralvarado |  | Designation of the Bactofiltration as a CCP was based on the Tetra Pak Manual | Conduct of HACCP Review and re-assessment to classify if bactofilter is a CCP or an Oprp. | CGabutero and FS Team | Started HACCP review on April 28, 2021 | Closed
March | ISO 9001 | NC3 | Minor | Internal Audit | Process of internal auditing has not been appropriately aligned with the ISO 9001;2018 requierments. | Included ISO and other appplicable standards in the Internal Audit Report Form | CAJawa |  | Internal Audit report used BRC standard as a baseline due to the specificity in the clauses. IQA Checklist also includes other standards such as ISO 9001 and 22000 but was not reflected in the audit report | Update and consolidate masterlist of all applicable standards for IQA into one database and grouped applicable clauses into one. In making the audit checklist, applicable clauses from the different standards will be used | CJawa | Started on April 24, 2021 | Closed
April | HALAL | NC1 | Minor | Halal Policy | Recurrence of findings from the previous Halal Audit on March 06, 2020 was found to be NOT ADDRESSED. This is the company Halal Policy which was NOT POSTED in company premises. | Reviewed and created layout for the Halal Policy to be posted around the company premises. | AHBPacalna |  | The previous findings was not completely revisited. | The halal policy, as well as the quality and food safety policy, vision, mission, and values, are now ready to print and display in our company premises. | CJawa |  | Closed
April | HALAL | NC2 | Minor | Documentation | There was no documented appointment for Halal Team Leader. | Create an appointment letter for the appointed CHAC and team members. | AHBPacalna |  | There was an appointment letter for the current  Company Halal Assurance Coordinator (CHAC) and team members, however this was not updated considering the previous CHAC is no longer connected with the organization. | Annual review of incumbent team members and succession planning. | [NAME] |  | Open
April | HALAL | NC3 | Minor | Competency | The organization has not systematically established the competency matrix to determine the necessary competence of members of the Halal Team as well as the members of the Halal Management Organization under its control that affects the performance and effectiveness of Halal Assurance System. Evidence: Failure to present competency matrix for members of Halal Team and Halal Management Organization. | Review the competence of each member in the [NAME] team. | AHBPacalna |  | No established competency matrix for the Halal Team. | Establish competency matrix for the members of the Halal team and provide necessary trainings. | AHBPacalna |  | Open
April | HALAL | NC4 | Minor | Documentation | Halal Team members were found to have no documented responsibilities. | Create confirmation of appointment  with documented position, functions and responsibilities, and assessment of qualifications confirmed by the team members. | AHBPacalna |  | No documented responsibilities. Functions and resposibilities was communicated verbally. | Incorporate documented responsibilities of the CHAC and team members in the HAS Manual. Review and update annually. | AHBPacalna |  | Closed
April | HALAL | NC5 | Minor | HAS Manual | Halal Assurance System (HAS) manual was found to have no evidence of approval by the top management. | Review the HAS Manual and update all the signatories. | AHBPacalna |  | Presented copy of the HAS Manual during the audit was a soft copy. | Cascade the HAS Manual in every department with their signature to confirm their awareness about the said manual. | CJawa |  | Closed
April | HALAL | NC6 | Minor | Documentation | Undocumented distribution of HAS manual. | Review the HAS Manual and update all the signatories. | AHBPacalna |  | Presented copy of the HAS Manual during the audit was a soft copy. | Cascade the HAS Manual in every department with their signature to confirm their awareness about the said manual. | CJawa |  | Closed
April | HALAL | NC7 | Minor | Documentation | Reference used in the development of HAS manual was noted to be the IDCP Handbook on Halal Assurance System for manufacturing company which is already outdated. IDCP-Halal Assurance Management System together with the IDCP-Halal Standard were not used as reference in the creation of this HAS Manual. | Ask a copy of the IDCP-Halal Assurance Management Systems from IDCP. | AHBPacalna |  | The development of HAS Manual was referred from the Sapphire Plant which used the IDCP-Handbook. | Review and update according to the IDCP-Halal Assurance Management Systems as a reference in the development of the HAS Manual. | AHBPacalna |  | Closed
April | HALAL | NC8 | Minor | Internal Halal Auditing | Standard/Criteria used in internal Halal Auditing was noted to be the IDCP Handbook and not the IDCP-Halal Assurance Management System. | Ask a copy of the IDCP-Halal Assurance Management Systems from IDCP. | AHBPacalna |  | The IDCP-Handbook is the only available standard/criteria for Halal Internal Auditing. | Revise the internal Halal auditing criteria based on the IDCP-Halal Assurance Management System. | AHBPacalna |  | Open
April | HALAL | NC9 | Minor | Receiving of Materials | There was neither a specific clause nor section in the incoming inspection procedure and receiving of packaging materials and ingredients that tells about the specific mandatory document requirements in receiving of materials. | Implement checking of availablity of documents in the incoming delivery inspection checklist and the Packaging  Material and Ingredients Status Tag. | AHBPacalna |  | Mandatory document requirement was generalized and not specified in the receiving of packaging and ingredient procedure. | Add detailed clause in the receiving of packaging and ingredient procedure that tells about the specific mandatory document requirements in receiving of materials. | ELucero |  | Closed
April | HALAL | NC10 | OFI | Halal Team | Not all the Halal Team members were present during the audit. | N/A |  |  | Shifting schedule of some of the  Halal team members. | Re-schedule shift of some team members whenever there is Halal Audit. | AHBPacalna |  | Open
April | HALAL | NC11 | OFI | Documentation | No table of contents. | Addidtion of table of contents on HAS Manual. | AHBPacalna |  | It was not taken into account when the Halal Assurance System manual was developed. | Reviewed and updated the Halal Assurance System Manual. | AHBPacalna |  | Closed
April | HALAL | NC12 | OFI | Training Needs Analysis | Training Description which is the "Halal Audit / Certification" was found to be not specific in Halal Assurance Subjects. | Update the Training Needs Analysis based on the description andrequirements of Halal. Revise Halal Audit/Certification into Halal Awareness Training. | KDDios |  | The Halal Audit/Certification was part of the Training Needs Analysis for the year 2021, however, the training description did not match with Halal's specified [NAME]'s assurance subjects. | To be more specific and to understand the Training Needs Analysis of the halal Team. | [NAME] |  | Closed
April | HALAL | NC13 | OFI | Suppliers Record | No section for country of origin. | Review the supplier's records and update the [NAME] database with the necessary details. | AANgni |  | The Halal Assurance System manual did not take this into consideration. | Revise HAS Manual to consider in the halal database. | PClenuar |  | Closed
April | HALAL | NC14 | OFI | Suppliers Record | No dedicated section for manufacturer. |  | AANgni |  |  |  | PClenuar |  | Closed
April | HALAL | NC15 | OFI | Suppliers Record | No prepared by and checked by. |  | AANgni |  |  |  | PClenuar, AHPacalna |  | Closed
May | Kellog's | NC1 | MAJOR | Monitoring System | The CCP 2 'Metal Detection Report (D-WHS-FR-01-03-03)' records on 5March 2021 were found to be recreated by Metal Detector Operator | Removed duplicate records for March 5, 2021 operation |  |  | Improper filing of records from shifting personnel causing records to be recreated for document review and product release. | [NAME] and Record Control Procedure to newly hired Warehouse personnel. Timeline June 15, 2021 | CJawa, LMontalban |  | Closed
May | Kellog's | NC2 | MAJOR | Documentation Control, Record Completion, Maintenance and Retention | The site did not ensure that recreation of any record is an unacceptable practice | Reviewed existing Procedures/WI to check if there were any policies prohibiting records duplication implemented on the site. |  |  | No procedure is in place for recreating, duplicating, and correcting of internally generated records | 1. [NAME] to include prohibition of duplicating records. Timeline: June 16, 2021 2. Cascade to Local document controller for implementation in their respective departments. Timeline: June 26, 2021 | CJawa |  | Open
May | Kellog's | NC3 | MAJOR | Pest Control | The PTL (Pest Threshold Limit) defined in 2021 is only by type of pest for each month. The Pest Trending report for Dec 2020 reported high Cigarette beetles infestation however Zero count reported under caught or sighting. The count for [NAME] fly, Phorid fly and [NAME] caught in the Warehouse 1st Floor were above PTL however there was no mentioned of corrective actions in the summary report. | Raised findings to Pest control provider and required them to indicate corrective actions done in the report for any findings observed. |  |  | Pest trending report did not summarize all pest management inspections carried on site. Corrective action done on pest activities exceeding the PTL is not yet captured in the monthly report | Revise monthly reporting to include corrective actions done on findings raised, PTL per area, and accuracy of report with regards to actual sightings and catches. | CGabutero |  | Open
May | Kellog's | NC4 | MINOR | Critical Control Points (CCPs)/Critical Limits | The site CCP Metal Detector sensitivity for all 3 test pieces do not meet Kellogg's requirement. | Requested purchase of test pieces (Fe: 1.5mm, Non-Fe: 1.5mm, [NAME]: 2.0mm) target up to Q3 2021. |  |  | Equipment sensitivity was updated but not validated against the higher sensitivity. Current setting (Fe:2.5mm, Non-Fe: 3.0mm, and [NAME]) was not updated as it is still in compliance to existing customer and regulatory standards. | 1. Revise Validation plan for CCP 2 Metal Detector to consider [NAME] requirement. Timeline: June 21, 2021   2. Conduct validation for metal detector with the updating setting and using the newly purchased  test pieces. Timeline: Q3 2021 3. Revision of HACCP Plan for DCN to incorporate changes in the CCP and use validation results as reference to re-assess risks. Cascade to FS Team and Operations team changes in the HACCP for DCN. Timeline: Q3 2021 | GZulueta, CGabutero |  | Open
May | Kellog's | NC5 | MINOR | Corrective Action Plan | The site defined that corrective action shall be taken for oPRP 3 on metal trapped on magnets if it exceeds usual quantity and/or unusual in nature however there is no procedure that detail on the specific maximum limits by quantity or the unusual nature. | Revision of HACCP Plan for DCN to incorporate internal standard based on collection data |  |  | Internal practice of using 0.06g fines collection was not documented. | 1. Revision of Control of Extraneous Matter procedure to include quantifiable limit of metal fines trapped in in-line plate magnets. Timeline: June 16, 2021 2. Cascade to production and QA personnel revised document: Timeline June 19, 2021 | BVillocino |  | Open
June | ISO 22000 | NC1 | Minor | Corrective Action | No evidence found on corrective actions being taken for the non-conformities raised in the last internal audit cycle , IQA Checklist 2020, and for the process nonconformities raised for finished products. Hold notification, material hold notification No: HN-ANL-DCN-21-167 | Create an NC report linked to IQA. | SSDop | 2021-06-28 00:00:00 | Centralized CAR Issuance. Process non-conformities are issued with CAR based on failed KPI monthly. | Revised CAR procedure to separate IQA findings and include issuance of CAR per non-conformities. | JSAnib | 2021-06-29 00:00:00 | Closed
June | ISO 22000 | NC2 | Minor | Document Control | It was observed the following records do not carry document control information eg. competency analysis, individual delivery plan  , IQA checklist | Enrolled documents to Plant Document Controller | CAJawa | 2021-06-28 00:00:00 | Mentioned records were newly implemented by the plant and Local Document Controllers were new without any training on Document Control | Conduct Document Control Training to PDC and LDCs | CJawa | 2021-07-02 00:00:00 | Closed
June | ISO 22000 | NC3 | Minor | Risk Assessment on Interested Parties | Following parties have not been considered eg. Competitors, Personal/Establishments provide emergency services – fire, hospital, police etc, reference: Risk assessment – understanding the context of the organization, D-QFS-OD-01, Rev: 02, page 9 -11 | Revised risk assessment | CAJawa | 2021-06-29 00:00:00 | Competitors, Personal/Establishments provide emergency services – fire, hospital, police etc, were not considered in the risk assessment. | Revision of the IMS Manual to define Internal, External, and Interested Parties | CAJawa | 2021-06-29 00:00:00 | Closed
June | ISO 22000 | NC4 | Minor | Buiding and Maintenance | Factory premises floor is peeled off in several areas, and cracked . | Repair of cracked flooring at VCO Warehouse | MRHollanes | 2021-06-05 00:00:00 | For peeled off paints, current repainting frequency is set at 3 years For cracked floor, earthquake encountered introduced cracks in the area | [NAME] schedule from 3 yeears to 1.5 years especially for frequently traffic areas. Repair of damaged flooring | MRHollanes | 2021-06-05 00:00:00 | Closed
June | ISO 22000 | NC4 | Minor | Buiding and Maintenance | Some open metal surfaces are rusty | Repainting of rusty surfaces - wet area | MRHollanes | 2021-06-05 00:00:00 | Area is not included in the facility inspection and is not frequently used due to no operation of coco milk line | Include area in the facility inspection | MRHollanes | 2021-06-05 00:00:00 | Open
June | ISO 22000 | NC4 | Minor | Equipment Maintenance | Cartons are used to cover pasteurizing units | Removal of cartons | RAlvarado | 2021-06-07 00:00:00 | Cartons were used as temporary protective measure to protect HMI from any unwanted damage by personnel during shutdown | Issued memo on for shutdown activities | RAlvarado | 2021-06-07 00:00:00 | Open
June | ISO 22000 | NC4 | Minor | Buiding and Maintenance | Cracks on the metal filter at the water extraction area,  semi processed coconut products are spilling to the ground | Repair of metal filter cap - extraction area | MRHollanes | 2021-06-05 00:00:00 | Equipment is not designed for frequent removal | Design modification to allow frequent removal | MRHollanes | 2021-06-05 00:00:00 | Open
June | ISO 22000 | NC4 | Minor | Buiding and Maintenance | Water stagnation  at the extraction area | Declogging of the clogged drains to remove dirt build up | MRHollanes Ralvarado | 2021-06-07 00:00:00 | Personnel practice to remove clogging damages the drains causing stagnation | Install strains (in good condition) in the area.  Issue memo and cascade proper cleaning of the area | MRHollanes Ralvarado | 2021-06-07 00:00:00 | Open
June | ISO 22000 | NC4 | Minor | GMP | Some staff maintain long nails | Pull-out personnel | BGVillocino | 2021-06-07 00:00:00 | Lack of awareness on GMP | Conduct refresher course on GMP Post GMP Visual boards on all Decon Areas | BGVillocino | 2021-06-07 00:00:00 | Open
June | Hershey | NC1 | Minor | Equipment Verification | Metal Detector and rejector system have verified by external however the effectivity of response time of the kick arm as being rejector has not measured and documented yet. |  |  |  |  |  |  |  | Open