Halal_assurance_system_has_for_foodservi.pdf

HALAL ASSURANCE SYSTEM (HAS) For Foodservice Organization and Food Manufacturer

AHMAD SAHIR JAIS

Intentionally left Blanks

HALAL ASSURANCE SYSTEM (HAS) For Foodservice Organization and Food Manufacturer

Published by POLITEKNIK MERLIMAU MELAKA Karung Berkunci 1031, Pejabat Pos Merlimau, 77300 Merlimau Melaka.

HALAL ASSURANCE SYSTEM (HAS) For Foodservice Organization and Food Manufacturer Copyright © 2016 by Ahmad Sahir Jais All rights reserved. Published in Malaysia. No part of this book may be used or reproduced in any manner whatsoever without written permission except in the case of brief quotations embodied in critical articles or reviews. All sources in this book are gathered from public domains as stated. All Work, Pictures, figure & data and sources are quoted and credited to the original author. For information contact; [email protected] Book and Cover design by Designer ISBN: First Edition: February 2016

Printed in Malaysia Printer Koperasi Politeknik Merlimau Berhad Politeknik Merlimau

Intentionally left Blanks

FOREWORDS

Halal Assurance System (HAS) is an integral part of a company’s halal integrity, especially for halal certification purposes. It will ensure that halal practices is implemented, company-wide, with accuracy and diligent. With HAS, the level of products and services reliability and consumer confidence will increase, knowing that halal is adopted systematically and according to Shariah law. To set up a HAS system, simplistic yet functional, is not an easy task. It requires commitment from all stakeholders, especially the management and the employee. The main objective of HAS is to minimize halal risk, reducing the fallout in the worst case scenarios and eventually initiate a corrective action. This book will help foodservice managers and food producers in creating HAS system within their organization. The setting up process is based on the Halal Certification Manual Procedure (2nd Revision 2014) and The Guidelines for Halal Assurance

Management

System

2012

develop

by

JAKIM.

TABLE OF CONTENTS CHAPTER 1 INTRODUCTION ....................................................................... 1 CHAPTER 2 MANAGEMENT RESPONSIBILITIES ................................... 7 A.

Training ............................................................................................... 8

B.

Internal Halal Committee ........................................................... 10

CHAPTER 3 HALAL ASSURANCE SYSTEM ............................................. 15 Halal Assurance System ............................................................................. 15 A.

Setting Up Halal Assurance System ....................................... 16

i.

Halal Assurance Planning ........................................................... 17

ii.

Creating Halal Policy .................................................................... 17

iii. Formation of Internal Halal Committee (IHC).................... 19 iv. Setting HAS Objective ................................................................. 19 v.

Creating HAS Manual Procedure.............................................. 19

vi. Creating SOP and Term of References .................................. 21 vii. Plan an Internal Halal Auditing ................................................ 23 viii. Familiarization & Socialization .................................................. 23 ix. Conduct Internal Audit & Evaluation ..................................... 23 x.

HAS Approval .................................................................................. 24

CHAPTER 4 REQUIREMENT IN HAS ........................................................ 25 i.

Determination of Halal Critical Point (HCP)......................... 29

ii.

Development and Verification of Flow Chart ...................... 39

iii. Implementation of control measure....................................... 46 iv. Development of corrective action ........................................... 47 v.

Documentation and management of records ..................... 50

vi. Process Verification ...................................................................... 52 B.

Halal Assurance System Manual Content ............................ 57

CHAPTER 5 INTERNAL HALAL AUDITING ............................................. 59 Objectives of Internal Halal Audit ....................................................... 60 Benefits of Internal Audit ....................................................................... 61 Advantages of Halal Internal Audits .................................................. 62 Disadvantages of Internal Audits ........................................................ 62 a)

Requirement .................................................................................... 62

i.

Authority ........................................................................................... 62

ii.

Scope of work ................................................................................. 63

iii. Competent Auditor........................................................................ 64 iv. Auditing Process ............................................................................ 66 Audit Planning & Preparation ............................................................ 67 Audit Execution ...................................................................................... 68 Audit Checklist ........................................................................................ 74 Opening Meeting .................................................................................... 75 Closing meeting ..................................................................................... 77 Review Audit findings .......................................................................... 79 b)

Reporting .......................................................................................... 80

Audit Finding and Preparing Audit Report ................................... 80 c)

Non-Conformances Record ........................................................ 82 NCR categories ....................................................................................... 83

CHAPTER 6 PRODUCT RECALL ................................................................. 85 i.

Type of Product Recall ................................................................. 85

ii.

Level of Recall ................................................................................. 86

iii.

Dissemination of Product Recall Notices .............................. 86

iv.

Product Recall Process ......................................................................... 87

CHAPTER 7 TRACEABILITY ........................................................................ 90 APPENDICES ......................................................................................................... 96 HAS MANUAL CONTENT & TEMPLATE ................................................................. 96 Approval Page .................................................................................................. 98 Distribution List ................................................................................................ 99 Amended List ................................................................................................. 100 Company Profile ............................................................................................. 101 Implementation Objectives ........................................................................... 102 Implementation Scope ................................................................................... 103 Halal Policy ..................................................................................................... 104 Halal Guidelines ............................................................................................. 105 Internal Halal Committee ............................................................................... 107 Management Review System ........................................................................ 109 Standard Operating Procedure – SOP ............................................................ 110

Working Instruction................................................................................... 112 Halal Critical Point (HCP) ................................................................................ 113 Control Measure & Corrective Action............................................................ 117 Administration System ................................................................................... 118 IHC meeting minutes...................................................................................... 119 Halal Training ................................................................................................. 120 Halal Socialization Program ........................................................................... 121 Internal Halal Audit System ........................................................................... 122 Halal audit Checklist ....................................................................................... 123 Non-Conformity Record (NCR) Reports ......................................................... 124 REFERENCES ....................................................................................................... 126

Intentionally left Blanks

CHAPTER HIGHLIGHTS At the end of this chapter, readers will be able to:  Understand on the Importance of Halal assurance system in preserving halal integrity

CHAPTER 1 INTRODUCTION

W

hen a company wants adopt halal certification,

proper halal assurance

system (HAS) must be put in place

prior to the use of the halal logo. This is to ensure the sanctity and purity of the halal product, produce by their respective manufacturer. When adopting HAS, the management are said to, “Systematically

put

the

whole

process

of

manufacturing to be monitored and scrutinized for any threat to halal”. The system is based upon the concept of total quality management and runs simultaneously

with

good

manufacturing

standards.

1

(GMP)

 Understand Halal integrity from Farm-to-Fork.  Understand in Setting up Halal assurance system for foodservice operator and food manufacture.

HAS act as an internal mechanism in monitoring, controlling, improving and preventing non-conformities at halal critical point (HCP) [1]. It is the responsibilities of the manufacturer to create, implement and maintain HAS. It can be applied in various types of industry such as food, drugs and cosmetics industry in a large as well as small scale, also possible for service based industry e.g. importer, distributor, transporter, and retailer. As term of reference, discussion in this book will be based upon there following standards, directives, statute and legislation: 

MS1500: 2009 Halal Food - Manufacturing, Preparation, Handling and Storing – General guideline (Second Revision). [2]



Food Act 1983 (Act 281) [3]



Food Regulations 1985 [3]



Regulation-Food Hygiene Regulations 2009. [3]



Decreed issued by The Fatwa Committee, National Council For Islamic Affairs or Fatwa decreed by the state authority



Halal Certification Manual Procedure (3rd Revision 2014) [4]



The Guidelines For Halal Assurance Management System 2011 [1]

Muslims regards halal as a responsibility, where the priority surpasses above any other requirements, when the situations permit. To seek halal is obligatory; therefore it is a sin to do otherwise. But at these moment it time, in a setting of multi-cultural, multi-religion environment, the risk of haram is evidently cannot be brush aside. Due to these changes, halal certification is introduced to give an assurance to the Muslim population on their food choices, among others. Selfdeclaration is no longer an accepted norm where its integrity is questionable. Even if the food operator

by default is a Muslim, there is not 100 percent 2

guaranteed that the food cooked, serve and sold are halal. The issues of halal move further away from the issues of pork and liquor, rather than starts at the point where the food is breed, cultivate and process. This give raised to the concept of “Farm-to-Fork” [5]. Farm-to-fork in halal tries to set the highest integrity level at all point of the supply chain. The contamination and non-compliances can occur at every level of these chains, therefore maintaining its integrity takes a lot of effort. FIGURE 1.1 The Concept of Halal From Farm-to-Fork PRE PRODUCTION LEVEL

PRODUCTION LEVEL

POST PRODUCTION LEVEL

ANIMAL FEED / FERTILIZER

PRODUCTION

PACKAGING

BREEDING / CULTIVATING PRACTICES

STORING/ WAREHOUSING

TRANSPORTATION

RAW MATERIAL PROCESSING

TRANSPORTATION

MERCHANDIZING

FIGURE 1.1 shows the concept of Halal Farm-to-Fork concept. Halalness need to find out during pre-production level at the farm, during production at the kitchen facilities and factory, and up to the point where the food and product are display before consumption by the end-user.

3

A few a years ago, Muslim communities were shocked to find that, Freshwater catfish, raised in aquaculture farm were fed with pig carcass and other impure food sources, hence renders the fish as haram. The majority of Muslim consumer didn’t know about this; until it starts to viral off in the newspaper and the social media. A multinational butter manufacturer was also tainted with scandals where, porcine DNA was found in their products. It is then traced back to a repackaging plant in Malaysia, the contamination occurs during the packaging process. It could happen also during transportation of goods and also at the retail level. As a foodservice operator, being certified with halal certification is not an easy task. The application process itself is a daunting task, and could take between 3 to 6 month in the preparation process, a month to be audited and 1 to 3 month to get the results [6]. During the preparation process, all the necessary requirements needed by the certification bodies must be met, at least with a minimum standard.

In Malaysia for an example, the standards used for halal

food were MS1500:2009 that fall under the purview of the Trade Description Act 2011. By having said that, the uses for the halal logo, halal marking as well as halal accreditation are sanctioned by the laws. Under the new halal certification scheme, only a few organization are required to have HAS implement ted in their business operation. Those organizations are as follow:

4

TABLE 1.1: Business That Has Been Required By JAKIM to Set HAS In Their Operation FOOD PRODUCT/ BEVERAGES / FOOD SUPPLEMENT [1] NO 1 2 3 4

CATEGORIES MULTINATIONAL MEDIUM SIZE SMALL SIZE MICRO

TERM OF REFERENCES Halal Certification Manual Procedure (3rd Revision 2014)

REQUIREMENT HAS Required

FOR

The Guidelines For Halal Assurance Management System 2011

Not Required

TERM OF REFERENCES

REQUIREMENT FOR

FOOD PREMISES NO

CATEGORIES

HAS 1

Restaurant, Canteen/ café

2

Chain Restaurant

3

Franchise Restaurant

4

Hotel ( Kitchen / restaurant) Cafeteria in Food court ( Centralized Management) Catering / Foodservices/ Convention center kitchen/ centralized Kitchen

5 6

7

Kiosk

8

Mobile outlet ( with centralized management/ kitchen

9

Halal Certification Manual rd

Procedure (3

Required

Revision

2014) The Guidelines For Halal Assurance Management System 2011 Not Required

Bakery shop/ cake / pastry

Source : [1], [4]

5

TABLE 1.2: Industry Classification INDUSTRY Small Industry

Small & Medium Industry (SME) Multinational Industry

       

TYPE Annual sales value RM 500,000 No of workers 50 Example: Village industry Annual sales value RM 500,000 to RM 25 million No of workers 150 Global business with network in a few countries Annual sales value of RM 25 million More than 150 workers

Source: [7], [6], [8]

6

CHAPTER HIGHLIGHTS

CHAPTER 2 MANAGEMENT RESPONSIBILITIES

H

alal certification requires commitment and

resources

Management

must

to be

accomplished. committed

to

ensure halal is implemented as a quality system rather than just a religious obligation. HAS requires total conformances to the standards with minimal or no error happens during the production procedure. This chapter will be discussing the responsibilities of the management in implementing HAS. Management is responsible to give training on halal matters as well as setting up an Internal Halal Committee (IHC) [2], [9]. Below are the discussions on the management responsibilities.

7

At the end of this chapter, reader will be able to:  Asses the Responsibilities of management in term of training and setting up halal committee.  Why training to Stake holder in halal training, the management, employees and suppliers are important.  How to set up an Internal Halal Committee (IHC).  Function and responsibilities of IHC.

A. Training First, the management shall provide adequate and continuous training on halal matter to their respective staff. IHC member especially, must be well versed with the Malaysia halal standards and its implementation. Periodic assessment on the employee general knowledge on halal matters shall be conducted in order to effectively deliver on their roles and responsibilities. Company need to conduct training for all staffs and employees. Company must identify topic of training in a certain period. Training must involve all personnel’s whose jobs may affect the halalness of the products. The objectives of training are: 

To improve employee’s knowledge on the importance of the halalness of product, critical points of materials and process.



To make employees understand the Halal Assurance System.

Not only that training also be conducted at all level of the supply and production chain. Even the cleaners need to be educated on the importance and basic of halal.

8

FIGURE 2.1: Stakeholder in Halal Training

Halal Training Top Management

Employees

Suppliers

Top Management The top management includes board member, Managers and executive. These are the most important people in the organization in terms of policy planning and execution. Halal implementation and commitment towards HAS need to come from the top level management. They need to be exposed on the importance and benefits of halal, implementation of halal as well as the repercussion of violating the halal standards. Employees The employees include the first line managers, Supervisor and general employee. These are the people that run the production on day to day basis. The need to be trained in halal is critical as they are the one who verify the compliances to halal standards. All employees must be given at least training on halal first, later on moving towards implementing HAS. Refresher course on halal must be conduct periodically to assess the readiness in adopting HAS.

9

Suppliers The supplier is the third critical in terms of training. The needs for a supplier that can conform to the halal standards are important to ensure halal throughout the supply chain. A well informed and trained supplier will be able to help in the procurement process by delivering materials that conformed to the specification. This eventually will reduce cases of non-conformity in the organization. B. Internal Halal Committee Apart from give training on halal, the management must create a working Internal Halal Committee (IHC). IHC are a group of employee, specially appointed by the management to manage and run the halal system in a company. It has a define hierarchy structure, given responsibilities and authority to conduct any halal related activities in the companies. The break down for IHC are as follows [4]. The IHC shall consist of AT LEAST, Four (4) members where: i.

Two (2) of the members must be practicing Muslim at management level.

ii.

One

(1)

of

the

members

is

responsible

for

purchasing

and

procurements process as in FIGURE 2.2. iii.

The highest ranking officer in charge for halal matters in the organization shall be the coordinator/ head of the IHC. 

For Halal slaughterhouse, Abattoir, halal supervisor shall be included in the IHC.

10



If the company has a dedicated halal executive within the company structure, therefor the task to be the head of IHC will be bestowed upon him.



The IHC shall be conferred with the necessary authority/autonomy to conducted audits, monitoring and implementing relevant policy that cover halal matters. The proper terms of reference for IHC must be established and acknowledge by the management.

FIGURE 2.2: Example of Internal Halal Committee Structure

Top Level Management

Head of Committee

Secretary

Operations/ Production

Technical / QA / QC

Procurement

R&D

As shown in FIGURE 2.2 and FIGURE 2.3, the IHC starts with the head of committee. The top level management, even though does not directly involved in IHC, they do play a vital roles in overall function of HAS. They are basically the key policy and decision maker in the company. Recommendations from IHC especially relating to NCR must be presented to the higher ranking management

11

for immediate action that concerns with company halal policy, management and cost that could incur during the process. The head of the committee is the one who create, implement and monitor the overall function of the HAS system. He or she, also serves as a role for coordinating and communicating function between top level management and IHC teams. Most often, it is the duty of halal executives to be the head of the committee. A dedicated secretarial position need to be created specifically for HAS system. It main tasks, is to maintain and process all the documentations related to HAS system. IHC also need to include participations from each or other branch of the company, ideally representing each steps in the process flow. For an example in FIGURE 2.3, participations will come from the production, purchasing and procurement, Technical/ Quality Assurance (QA) & Quality Control (QC) as well as Research & Development (R & D). These people are they key personnel that deals directly with the HAS system.

12

CREATING, IMPLEMENTING AND MONITORING HAS

DOCUMENTATI ON AND RECORD KEEPING

OPERATIONAL COMPLIANCES. APPLICATION AND MONITORING OF HAS Operations/ Production

POLICY MAKER

TOP LEVEL MANAGEMENT

FIGURE 2.3: Internal Halal Committee Task and Designation

Procurement HEAD OF COMMITTEE

SECRETARY Technical / Qa / Qc R&D

The committee members must be well trained on halal matters. Member of the IHC must be periodically refreshed on halal training. The effectiveness of IHC shall be periodically review by the management at least once a year. Reviews are necessary when there are: i.

Changes in the company policy, product, supply chain

ii.

Changes made to the monitoring schedule

iii.

Changes in the IHC

13

FIGURE 2.4: Example of Internal Halal committee.

In FIGURE 2.4, depiction an example of halal committee structure in HAS manual. Management responsibilities and commitment are needed in the implementation of HAS system. Continuous training within the ranks will eventually reduce the halal risk through work efficiency and adherence to the standards. IHC meanwhile are needed to perform the management task of halal, making sure that halal are implemented throughout the company.

14

CHAPTER HIGHLIGHTS At the end of this chapter, reader will be able to:  Understand what is Halal Assurance system (HAS)  Identify steps in creating HAS system  Design and conceived ideas on creating Halal Assurance system.

CHAPTER 3 HALAL ASSURANCE SYSTEM Halal Assurance System Halal assurance system or HAS, is a systematic planning,

implementation

of

documentation

managing

halal

in

relation

production. planning

integrity

Creating

a

credible

and coordination

HAS

to

in

food

requires

from various parties

within that particular organization. It is also time consuming, and requires diligent approaches when implemented. When applied correctly, HAS will help

15

in maintaining and sustaining halal integrity system throughout the entire supply chain. Setting Up Halal Assurance System

Since setting up HAS requires careful planning, steps must be taken to form them. Below are an example of the steps that could be used in setting up HAS, the basic steps in setting up a HAS system are illustrated in FIGURE 3.1. FIGURE 3.1: Steps in setting up halal assurance system [10] REVISION

HAS planning

Creating Halal Policy

IHC Formation

Setting HAS Objective

Creating HAS Manual

Creating SOP, term of references

Plan an Internal Halal Auditing

Familiarization & Simulation

Conduct Internal Audit & Evaluation

HAS Approval

Sources: Steps in setting up Halal Assurance system (Adapted from General Guidelines Of Halal Assurance System - LPPOM MUI.” The Assessment Institute For Foods, Drugs And Cosmetics Indonesian Council Of Ulama (LPPOM MUI) (2012)

Those steps illustated in FIGURE 3.1 are sourced from General Guidelines Of Halal Assurance System, The Assessment Institute For Foods, Drugs And 16

Cosmetics, Indonesian Council Of Ulama [10]. It requires 9 steps in setting up a HAS system. Discussion on the setting up process are as follows. i.

Halal Assurance Planning

The first step is planning. HAS is very clear and defines set of task that governs the halal integrity in an organization. Setting up a working system is not an easy task. The system must be free from error so that its effectiveness in maintaining whatever task it intended to be eventually become successful. The first step in setting up HAS is to determine the needs for one. For halal certification purpose, it is necessary to have one as it is one of the criteria look for in the certification process. HAS planning requires commitment from the management in term of resources. The management shall in its best abilities provide all the necessary resource, monetary, man power and willingness to conform itself with the halal assurance system. ii.

Creating Halal Policy

The next step is to formulate a halal policy. Halal policy will dictates the overall HAS implementation, as well as the strategy to create, operate and maintain a systematic HAS. Halal policy is a declaration, a written statement of company commitment to produce halal product continuously and consistently. Halal policy are

considered

as

fundamental

of

a

company

in

term

of

setting

up,

implementing, monitoring and evaluation and necessary corrective action of HAS. Halal policy should at least, consist of these elements: 

Brief background of the company.



General statement of the company readiness level in implementing halal.

17



Company mission and vision in implementing and adopting halal in their corporate structure



The company pledge towards customer expectation on halal



Tools, method and task the company tool to implement halal system.

FIGURE 3.2 illustrated a simple halal policy statement for a foodservice organization. FIGURE 3.2 Example of Written Halal Policy

18

iii.

Formation of Internal Halal Committee (IHC)

After a proper halal policy has been laid out, then there are the needs to create an Internal Halal committee (IHC). The inner working of IHC has been discussed in Chapter 2. iv.

Setting HAS Objective

The next steps after formation of IHC were to set and defined objective of HAS. In general, HAS is created to ensure the systematic application and monitoring of halal in the organization. The objectives of HAS are as follows: 

To

ensure

the

integrity

of

Halal

processing

by

continuously

and

consistently monitored on the compliance to the Shariah (Islamic Law). 

To ensure compliance to all guidelines issued by halal Certification authorities such as Halal Assurance Management System of Malaysia Halal Certification produced by Department of Islamic Development Malaysia (JAKIM).



To ensure compliance to the Malaysia Standard MS 1500:2009 Halal Food Production, Preparation, Handling and Storage – General Guideline (Second Revision) produced by SIRIM.

Apart from that, HAS are vital as a benchmarking and guiding tools as it is well documented. v. Creating HAS Manual Procedure Depending on the objective that has been set up, the IHC task are to set up a working halal manual procedure. Halal manual procedure contains all the task, process flow and inner working of the production line. 19

FIGURE 3.3: Front Cover of HAS Manual Procedure (Refer to appendices for full documents)

20

vi. Creating SOP and Term of References After the manual has been formulated, it then needs to be translated or converted into working standard operating procedures (SOP). SOP a set of standard instruction tools to complete a certain routine process. SOP is set up as standard procedure in HAS implementation. SOP is established for all activities in halal production process i.e. SOP for Research & Development, Purchasing, Quality Assurance /Quality Control, Production and Storage/Warehousing. Due to different complexity level in a company, SOP(s) are unique. Example of key activities in SOP for halal production is SOP for material purchasing, SOP for new material usage, and SOP for new supplier change. The process flow must follow the halal manual procedure and the SOP. This is to avoid any halal threat from manifesting itself as non-conformances. An example of Halal standard Operating Procedure as shown in FIGURE 3.3.

21

FIGURE 3.4: Example of Halal Standard Operating Procedure (refer Appendices for full documents) Halal Assurance System (HAS) – STANDARD OPERATING PROCEDURE

DEPARTMENTS

Purchasing and Procurement Dept.

DATE OF IMPLEMENTATION

1 January 2016

PROCESS OWNER

Purchasing Manager

VERSION

HAS/SOP/PC-01-2016

DESCRIPTION

TASK

1. Material purchased should conform to the list approved by JAKIM 2. Material purchased must conform to data mentioned in the halal certification documents. Check For : a) Bill of material b) Product Specification sheets c) Product code and SKU # 3. Check for Transportation (Vehicle Cleanliness, Not using transport which has been used to carry haram products. 4. Purchasing documents must be well documented (Delivery Order, Purchase request, Invoice etc.)

Purchasing Manager & Receiving Officer

Receiving Clerk & Production Manager

Purchasing Manager & Receiving Officer Purchasing Clerk & Finance Department

All rights reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission of company XYZ.

22

vii.

Plan an Internal Halal Auditing

An internal audit must be planned to check and compare practices and compliances against set standards, Manual procedure and term of reference for each departments. Planning for auditing must be set up in advance and need to be advocate within the organization. Further discussion on internal halal auditing in Chapter 5. viii.

Familiarization & Socialization

Prior to the actual auditing, employee need to be familiarize with HAS. Training and induction session must be conducted to educate and familiarize the employee on the importance of HAS. The familiarization not only limited among the employee but also must also be extended to third party such as supplier, transporter etc.

These activities are aimed at creating awareness of all

stakeholders on halal policy, in order to encourage them to apply it at operational level. Halal policy socialization could be in form of poster, leaflet, general lecture, internal bulletin, and supplier audit or company internal memo. ix.

Conduct Internal Audit & Evaluation

A system when left without proper monitoring and surveillance will collapse by itself. In HAS, audit process play a vital roles in the system monitoring and surveillance. Apart from the external audit conducted by the religious authority, internal audit are used primarily to make sure the system are in check. For further explanation and discussion on the internal halal audit, please refer in chapter 5.

23

x.

HAS Approval

After all criteria in the process flow has been satisfied, with marginal errors and discrepancies, the HAS manual are now ready to be approved and used in the organization. Periodical monitoring as well as assessment by the management are vital to ensure the integrity of the HAS system being implemented. The process of setting up HAS seems to be a complicated in nature, but given the importance of HAS in managing and controlling halal within an organization, having one is pivotal to the halal integrity of a company. All the said due process are essential in in the process of creating HAS systematically. For an example, HAS manual procedure are important because it contains all the necessary documentation in regards of the halal management.

24

CHAPTER HIGHLIGHTS

CHAPTER 4 REQUIREMENT IN HAS Halal hub division of the Department of Islamic Development Malaysia (JAKIM), in their certification process, requires applicants to set up a Halal assurance system. Halal assurance system requires and

applies

several

key

principles

in

its

implementation process. The key principles are as listed in FIGURE 4.1.

25

At the end of this chapter, reader will be able to: 1. Identify the requirement for Halal Assurance system mandated by JAKIM 2. Asses the Halal critical point (HCP) in the production process flow. 3. Know the documents found in a typical HAS system

However only certain categories of business are required to set up HAS system. Those categories are illustrated in TABLE 4.1. HAS were only required for a certain type of business ownership, particularly for the multinational and medium size industry for food manufacturing. As for foodservice operations, restaurant, canteen / café, chain restaurant, franchise restaurant, Hotel (kitchen /restaurant), cafeteria in food court with centralized management, Catering / Foodservices/ Convention center kitchen/ centralized were required to adopt HAS as part of the halal certification program. TABLE 4.1: Business that has been required by JAKIM to set HAS in their operation FOOD PRODUCT/ BEVERAGES / FOOD SUPPLEMENT NO

1

CATEGORIES

TERM OF REFERENCES

MULTINATIONAL Halal Certification Manual

2

REQUIREMENT HAS

MEDIUM SIZE

Procedure (3rd Revision

Required

2014) 3

SMALL SIZE

The Guidelines For Halal Assurance Management

4 MICRO

System 2011

26

Not Required

FOR

FOOD PREMISES NO

CATEGORIES

1

Restaurant, Canteen/ cafe

2

Chain Restaurant

3

Franchise Restaurant

4

Hotel ( Kitchen /

TERM OF REFERENCES

REQUIREMENT FOR HAS

restaurant) 5 6

Required

Cafeteria in Food court ( Centralized Management)

Halal Certification Manual

Catering / Foodservices/

Procedure (3rd Revision

Convention center

2014)

kitchen/ centralized Kitchen

The Guidelines For Halal Assurance Management

7

Kiosk

8

Mobile outlet ( with

System 2011

Not Required

centralized management/ kitchen 9

Bakery shop/ cake / pastry

Source : [1], [4] This ruling was made compulsory after the revision of JAKIM Halal Manual procedure in 2014.

27

FIGURE 4.1: Key Principles in Implementing Halal Assurance system

Determination of Halal critical point

Process verification

Development and verification of flow chart

Documentation and management of records

Implementation of control measure

Development of corrective action

Sources: [1] FIGURE 4.1 above illustrate the requirement for HAS system required by JAKIM as stated in the Halal Certification Manual Procedure (3rd Revision 2014) and The Guidelines for Halal Assurance Management System 2011. These are the minimum requirement mandate by JAKIM. The following discussion in this chapter will guide foodservice operator and manufacturer to set up a simple, yet functioning HAS system as required by JAKIM. The process of setting up a HAS must follow the steps shown in FIGURE 4.1. Those steps will be discussed further. As opposed to the setting up process suggested by Indonesian Council of Ulama, the Malaysian requirement for HAS 28

system has been simplified but it does not mean that the whole integrity of halal has been undermined. The essences of control are still there, but only certain requirements are left out. Below are the discussion on those 6 Steps in setting up HAS system mandated by JAKIM. i. Determination of Halal Critical Point (HCP)

The first step in setting up HAS is to identify halal critical point (HCP). HCP is the key process in the development of HAS. HCP is defined as Halal Critical Point is a location or process in the process flow where measures can be applied to eliminate failures to comply Shariah requirements. The HAS plan is developed around the HCP to ensure the integrity of the production and halalness of the product.



IHC shall determine any plausible source of haram risk in all aspect of the production, throughout the supply chain



risk assessment shall be done methodically and scientifically



it should be recorded and documented

In order to determine the Halal critical point, a simple but methodological approach develops by The Assessment Institute For Foods, Drugs And Cosmetics Indonesian Council Of Ulama (LPPOM MUI) can be used. This method uses a simple method of decision based upon yes or no answer [10]. Abilty to recognized and identify halal critical ingredients and process are vital in the HAS system. Rather than blindly guess whether that said material halal, haram and syubhah, this method systematically define and segregated the process and material into halal critical points (HCP).

29

FIGURE 4.2: Decision Tree HCP for Plant Based Product

PLANT PRODUCT PROCESSING

YES

NO

NON CP

MICROBIAL CULTIVATION

YES

NO

KHAMR FERMENTATION

ADDITIVE AND PROCESSING AID?

YES

NO

NO

YES

HARAM

HCP

NON CP

HCP

Source: Adopted from “ General Guidelines Of Halal Assurance System - LPPOM MUI.” The Assessment Institute For Foods, Drugs And Cosmetics Indonesian Council Of Ulama (LPPOM MUI) [10]

For plant based products, the risk for haram risk are low accept for plant based products that has been processed, especially those which has been into contact with microbial cultivation and additional preservative.

30

FIGURE 4.3: Decision Tree HCP for Animal Products ANIMAL BASED PRODUCTS

MILK, EGGS, FISH

MEAT AND BY PRODUCTS ( FAT, BONES,SKINS,MARROW HALAL ANIMAL

PROCESSING NO NO

YES

YES SLAUGHTERING ACCORDING TO SHARIAH LAW, POSSES HALAL CERTIFICATE

HCP NON HCP

HARAM

NO

YES

SYUBHAH / HARAM

FURTHER PROCESSING

YES

NO

HCP

NON HCP

Source: Adopted from “ General Guidelines Of Halal Assurance System - LPPOM MUI.” The Assessment Institute For Foods, Drugs And Cosmetics Indonesian Council Of Ulama (LPPOM MUI) [10]

As for animal based products, the critical point are more evident due to the nature of the raw material. Animal requires slaughtering and further processing rendering it vulnerable to haram risk. For animal based product, detailed attention must be given in the receiving and setting product specification. 31

FIGURE 4.4: Decision Tree HCP for Microbial products

MICROBIAL PRODUCTS

CP

Source: Adopted from “ General Guidelines Of Halal Assurance System - LPPOM MUI.” The Assessment Institute For Foods, Drugs And Cosmetics Indonesian Council Of Ulama (LPPOM MUI) [10]

All microbial products are critical. This is due to the type of medium the microbe are cultured on. The media, most of the time are sourced from haram ingredients such as pigs blood. Pigs blood are the most used media in microbe culturing proccess because of its effectiveness and cost concerns.

32

FIGURE 4.5: Decision Tree HCP for Other Material

OTHER MATERIAL

MINERALS

SYNTHETICS

MIXED CP

NON CP

ORGANIC

NON ORGANIC

CP

FOOD ADDITIVES

NO

YES

NON CP

CP

Source: Adopted from “ General Guidelines Of Halal Assurance System - LPPOM MUI.” The Assessment Institute For Foods, Drugs And Cosmetics Indonesian Council Of Ulama (LPPOM MUI) [10]

Other materials refers to mineral, synthetic and mixed based compound. For mineral such as rock salt, it does not has any haram risk apart from the way it was processed and mined. For synthetic based material derived from both organic and non-organic, attention must be given on the addition of material and additives.

33

FIGURE 4.6: Decision Tree HCP for Warehousing And Production Line

HALAL CERTIFIED MATERIAL YES RISK OF CONTAMINATION BY NAJIS AND HARAM MATERIAL

NO

HALAL PRODUCT MANUFACTURED BY COMPANY THAT ALSO MANUFACTURED NON HALAL PRODUCT

YES

NO

YES

HCP

NON HCP

HARAM/ SYUBHAH

NO MATERIAL OF NON CERTIFIED PRODUCT

NO

YES

PRODUCTION LINE AND STORAGE MATERIAL AND PRODUCTS FOR CERTIFIED AND NON CERTIFIED PRODUCTS SEPARATED YES NON CP

NO SANTATION PROCEDURE ELIMINATE FAT, SMELL, COLOR AND TASTE YES

NO

RISK OF CROSS CONTAMINATION BY HARAM AND NAJIS MATERIAL

NON CP

NO

YES

HCP

Source: Adopted from “ General Guidelines Of Halal Assurance System - LPPOM MUI.” The Assessment Institute For Foods, Drugs And Cosmetics Indonesian Council Of Ulama (LPPOM MUI) [10]

34

FIGURE 4.7: Decision Tree HCP for halal distribution DISTRIBUTED PRODUCT HALAL CERTIFIED

NO

YES NON CP

DISTRIBUTION TOOLS/EQUIPMENT DIFFERENT? YES

NO

NON CP

NON CERTIFIED HALAL PRODUCT CONTAIN PORK/HARAM/NAJIS? YES

NO WITH PACKAGING/PACKING?

HCP

YES

NO CP

PACKAGING AVOID CROSS CONTAMINATION? YES

NO

NON CP

CP

Source: Adopted from “ General Guidelines Of Halal Assurance System - LPPOM MUI.” The Assessment Institute For Foods, Drugs And Cosmetics Indonesian Council Of Ulama (LPPOM MUI) [10]

35

FIGURE 4.8: Decision Tree HCP for Halal display PRODUCTS ON DISPLAY ARE HALAL CERTIFIED? NO

YES

SEPARATED DISTINCTLY?

NON CP

YES

NO

NON CP HALAL CERTIFIED PRODUCT CONTAIN PORK/HARAM/NAJIS? YES

NO

CP

PACKAGING/PACKING YES

NO

NO CP

CP

Source: Adopted from “ General Guidelines Of Halal Assurance System - LPPOM MUI.” The Assessment Institute For Foods, Drugs And Cosmetics Indonesian Council Of Ulama (LPPOM MUI) [10]

In MS 1500:2009 one of the criteria listed in the requirement for halal certificate is the display of halal food. Food, mostly finished products must be separated from halal and non-halal food. Food that potentially will come into contact with non-halal should be given attention especially if the item has no proper packaging.

36

FIGURE 4.9: Decision Tree HCP for Halal Slaughtering

MEAT AND POULTRY

MUSLIM SLAUGHTERMAN

YES

NO

ACCORDANCE TO SHARIAH LAW

NO

HARAM

YES

HCP

STUNNING PROCESS NO

YES

HCP

SHARP IMPLEMENT YES

NO

HCP

SWIFT PROCESS AND DIES INSTANTLY FULL BLOOD DRAINAGE YES

NO

HCP

Source: Adopted from “ General Guidelines Of Halal Assurance System - LPPOM MUI.” The Assessment Institute For Foods, Drugs And Cosmetics Indonesian Council Of Ulama (LPPOM MUI) [10]

37

FIGURE 4.10: Decision Tree HCP for material status

ARE THE MATERIAL IMPORTED? YES

NO

DO THEY HAVE HALAL CERTIFICATE OR CERTIFICATE FROM CERTIFIED HALAL BODIES RECOGNIZED BY JAKIM, AND VALID? NO

ABLE TO OBTAIN HALAL CERTIFICATE?

YES

NO

YES

IS THE MATERIAL CONTAINING SYUBHAH INGREDIENTS (ANIMAL PRODUCTS, KHAMR? NO

YES

HALAL CERTIFICATION NO

ASSESMENT FROM JAKIM CP

YES

NO CP

MATERIAL CANOT BE USED

MATERIAL CAN BE USED

Source: “General Guidelines Of Halal Assurance System - LPPOM MUI.” The Assessment Institute For Foods, Drugs And Cosmetics Indonesian Council Of Ulama (LPPOM MUI) [10]

38

In reference to FIGURE 4.2 to FIGURE 4.10, it illustrates how HCP can be identified individually, for each raw material, and also at the department or processing level. IHC must list down all the proses flow that directly involved with the procurement, storing, processing, production, transporting and merchandising the halal products. Identifying HCP is the most crucial steps in creating HAS, as it is the core of HAS system. The next steps is to develop and verify the process flow chart. ii.

Development and Verification of Flow Chart

The whole supply chain and production flow shall be translated in into flow chart. Each step in the flow chart should be benchmarked with the actual process so that none will be left out. The flowcharts will be used as a tool by the IHC to determine any plausible risk of haram contamination. In FIGURE 4.11, FIGURE 4.12 and FIGURE 4.13, the HCP are clearly defined and identified prior to operation. Appropriates control measures then must be established to prevent any occurrence of haram risk.

39

FIGURE 4.11: Example of Process Flow in HAS manual

40

FIGURE 4.12: An example of Halal Critical Point in Bread Making

RAW MATERIAL

MIXING

HCP 1

DOUGH MAKING

PORTIONING

PAN GREASE

DEPOSITS IN PAN

HCP 1

BAKING AND SLICING PACKAGING AND LABELING

HCP 1

Source : Adapted from M. N. Riaz and M. M. Chaudry, Halal Food Production. 2004 [11]

41

FIGURE 4.13: Prosess flow in Purchasing with Halal Critical Point (HCP)

product specification

supplier submit product specs

HCP 1

Check For halal Certificate

HCP 2

NO YES

Purchase List

HALAL TRANSPORTATION

Receiving

HCP 3

YES

NO

Comparing With Products Specs REJECT SHIPMENTS

Storing

42

HCP 4

FIGURE 4.14: Example of a process flow in HAS manual

43

FIGURE 4.12 and FIGURE 4.13, illustrates the production flow chart for baking white bread. In each steps of the process, HCP should be determines at a certain juncture and critical point where halal threat could occurs. In the above example, HCP has been detected at mixing process, panning and packing. HCP 1 denotes the possibilities of halal and haram contamination at the mixing stages, where non halal ingredients could be intentionally or unintentionally add into the mixture. HCP 2 deals with possible contamination of greasing or releasing agent used in the baking process, while HCP 3 deals with possible contamination sourcing from the packaging material.

Control measures must be created to

avoid all the risk from happening. Identifying HCP also start from other elements of

the

supply

chains.

These

include

purchasing

as

well.

When

taking

consideration the farm-to-fork concepts, FIGURE 4.13 and FIGURE 4.14, identify HCP during in procuring and receiving process. For foodservice entities, organization-wide halal critical point must also be determined to ensure any possible risk area to be identified. Using a process flow greatly help in identifying risky area such as during preparing specification details, receiving and storage & production. FIGURE 4.15 illustrates how HCP areas are determined for the entire supply chain. It need to be analyze, in this case in a form of a process flow, and each critical area need to be identified.

44

FIGURE 4.15 Determinations of HCP Areas in the Supply Chain for a Foodservice Entity

45

iii.

Implementation of control measure

The third step in creating HAS, is to create and implement control measure. In the event of any haram risk detected in the process flow chart, the IHC shall instigate a corrective action to prevent the haram risk from happening. The corrective plan must also be taken in view of prevailing halal standard and Shariah laws. Control measures are action taken before the actual incidents happen. As illustrated in FIGURE 4.15, each critical areas that has been identified, and the next steps is to fragment the areas into specific task as shown in FIGURE 4.13, where the task in purchasing department is further elaborate and specific function task are defined. Each HCP in that particular flow must also contained control measure as well as corrective action. For each HCP that has been identified, a specific control measure must be developed. Control measure is a preventive action taken before the actual critical point manifest itself as an incidents. FIGURE 4.16; graphically illustrate how control measure and corrective action plan can be used in the production area. It is imperative that the control measures are doable and practical to be implemented at the rank and file level.

46

iv.

Development of corrective action

The next steps in HAS implementation is to create Corrective action. Corrective action must be taken before and after the halal risk, manifest itself into a fullblown incidents. Action must be taken immediately to uphold the halal integrity system. Corrective action are the continuity of the control measure instated in the HAS system. Corrective actions are divided into two situations when: 

HCP has been determined and the incidents yet to happened. Corrective actions are implemented to avoid the occurrences of the incidents.



HCP has been determined and the incident has happened. Corrective actions are implemented to

negate the outcome of the non-

conformances. These corrective actions can be integrated together with control measure as shown in FIGURE 4.16 IHC shall ensure that proper corrective action is taken and documented, ready to be presented and audited by certification bodies in needed. Products that are manufactured prior and during the ratification process must be separated. Appropriate procedure must be created to prevent any similar incidents from happening.

47

The incidents must be recorded. The documentation shall include: i.

Review of non-conformities

ii.

Investigation report that indicates whether the incidents happens due to human error, controllable or uncontrollable.

iii.

The cause of non-conformity

iv.

Pre-emptive measure taken to avoid similar incidents from happening again

v.

Record the results of corrective action

vi.

Assessment on the effectiveness of the corrective action taken

Corrective action for HAS implementation is taken if any non-conformities of implementation were found at a time of internal halal audit was conducted. The corrective action must be taken as early as possible, especially if it will cause a direct effect on product halal status. All forms of corrective action taken by companies must be well-documented in a written record.

48

FIGURE 4.16: Halal Critical point and corrective action measure

HALAL CRITICAL POINT (HCP) AND CORRECTIVE ACTION MEASURE DEPARTMENTS PROCESS OWNER

NO.

Production Line Manager

NAME MATERIAL Bread Improver

Grease Pan / Oleo Resin

DATE OF IMPLEMENTATION VERSION

HCP Contains lecithin

Contain Stearate, from animal product

Control Measure

1 January 2016 HAS/HCP/PROD-01-2016

CORRECTIVE ACTION

 Product Specification must be clear on the type and point of origins of the material  Proven halal certificate  Reputable and Known Brand  Recheck material packaging with the BOM  Product Specification must be clear on the type and point of origins of the material  Proven halal certificate  Reputable and Known Brand



  



  

VERIFICATION

Rejects if information on packaging does not correspond with halal certification Check for packaging integrity, no repack item be accepted Reject all batches if has been tainted Initiated line shutdown



Rejects if information on packaging does not correspond with halal Certification Check for packaging integrity, no repack item be accepted Reject all batches if has been tainted Initiated line shutdown







DOCUMENTATION

Check during receiving by receiving clerk Check by line supervisor at mixing station

Product specification

Check during receiving by receiving clerk Check by line supervisor at depositing station

Product specification

Receiving SOP

Receiving SOP

Controlled Documents. © All rights reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission of company XYZ.

49

v.

Documentation and management of records

IHC shall, in their best efforts to create and maintained a proper documentation records for the halal assurance system. A proper filing system, with dedicated storing space must be created to keep all the record. This will be used as evidence, when the needs arise. This record will show how effective the system being managed as well as its implementation system. The record shall be kept at minimum for one year. However it is advisable that the record to be kept indefinitely and properly archived. Each record and documents must be duly signed by the process owner together with dates. HAS is written in the form of Halal Manual, separately from other quality system manual(s) such as Hazard Analysis Critical Control Point (HACCP), ISO, etc. HAS Manual has to describe function of each division in company with person in charge and its distribution. For some function such as training, socialization, SOP, work instruction, form etc., and its implementation may be integrated with other quality system(s).

50

FIGURE 4.17: HAS Documentation Ownership and Responsibilities

Halal Manual (Top Management,Managers) Halal SOP (Managers, Halal Executives) Halal Technical References (Supervisor) halal working instruction (Production Employee)

Documents that needed to be kept in these records are: 

Manual of halal assurance system



The roles and responsibilities of IHC, and the roles and

duties for each

process owners in Halal Control Point (HCP). 

Minutes of IHC meetings



List of halal threats and HCP parameters



Instruction on the monitoring procedure and their corrective actions.



Material Purchasing documents such as products specification



Material receiving documents such as delivery order



Material Storage documents



Research and Development (Formulation) documents



Production (Production Process and Production Facility Cleaning) documents



Product Storage documents



Product Distribution documents



Evaluation and Monitoring (periodical report) documents



Training and Socialization activities documents



Improvements action for non-conformities documents



Management Review documents

51

vi.

Process Verification

The last steps in implementing HAS is to verify that all activities in the Halal Assurance plan are implemented correctly and effectively and in compliance with the Halal Standard requirements and Shariah law. Verification of HAS is divided into 2 Categories: i.

Verification of HAS activities to ensure all activities are done correctly.

ii.

Verification of HAS system to ensure the system is complete and effective to meet the objective of HAS.

A process Validation is carried out to ensure that the criteria developed at HCP is effective and to comply with Shariah requirements. The validation process is applied at all HCP. Revalidation and reassessment of HCP must be carried out when: 

Major changes happen that may affect the HAS system or when new study



New experiments method found that can improve the validation process



New fatwa or guidelines issued by the authority



Changes in the process flow or new products



The process verification shall be done to check whether the HCP are implemented

Tools that can used in order to check compliances are checklist, crosscheck with other departmental functions and previous audit reports.

52

FIGURE 4.18: NCR reports as a process verification tools

NON-CONFORMITY RECORD (NCR) REPORTS This report need to be attached with the Internal Halal Audit Checklist if any NCR incidents to Occur. One (1) Copy per incidents. Date : Time : Person In charge :

23 Nov 2015 10.30 pm Faizal

NO

Place : Auditor :

Production Line 1 Baharom

Prepared By:

Verified by:

Acknowledge by:

baharom

santha

faizal

NCR INCIDENTS / DETAILS DESCRIPTION One of the sacks containing bread improver has been found to be different from the original specification in terms of packaging at the mixing station. Initiating investigation with purchasing to find whether the material used are the same.

Description 1

2

REMARKS Purchasing has been Notified QA/QC has taken sample for porcine detection using rapid test kit.

The material is the same. Only changes with the packaging. Supplier didn’t notified purchasing dept. in advance

No Porcine detected using rapid detection kit

Level of NCR

( ) Minor ( / ) Serious ( ) Major

Cc to Purchasing Dept. Notification to suppliers

Process Flow

HAS/HCP/PROD-01-2016 HAS/HCP/PP-01-2016

FINDINGS OF NONCONFORMITY

CAUSE ANALYSIS Error Type

( ) Mechanical ( / ) Human ( ) Others. Please Specified

53

Late Notification. No Haram risk detected

NO

3

NCR INCIDENTS / DETAILS DESCRIPTION ( / ) Immediately ( / ) Time specific (2nd December 2015) Action Taken CORRECTIVE ACTIONS REQUESTs (CAR’S)

Supplier are warned to give ample notice before committing to any changes in their products

Status Due Date Requested By Verified By

REMARKS Production lines were stop and continued after clarification from the material supplier. Suppliers sent a new Material specification indicating changes in packaging material.

Corrected nd

2 Dec 2015

baharom santha

In the case of NCR Level Major, Total Shutdown of the production line must be initiated. IHC must be notified immediately.

NCR reports can be used as a measuring tools to see the process and system of halal being implemented in the organization. FIGURE 4.18 clearly show a sample of NCR reports. It contains all the necessary information regarding the halal system being implemented in the. The information contain in the reports are derived from the used of halal checklist. Halal checklist will objectively put in place a detailed and systematic evaluation towards the whole system. For example, an auditor will assess the effectiveness or implementation of HAS only at certain part of the production where it is necessary to put force HAS. An example of halal checklist is illustrated in FIGURE 4.19 below.

54

FIGURE 4.19 Sample of Halal Checklist

HALAL INTERNAL AUDIT CHECKLIST Date : Time : Person In charge :

23 Nov 2015 10.30 pm Faizal

Place : Auditor :

Production Line 1 Baharom

Prepared By:

Verified by:

Acknowledge by:

baharom

santha

faizal

Department/ Process Flow : Requirement in standards : RESULTS OF AUDIT NO.

1 2 3 4

5

6

7

8

9

10

11

12

QUESTION

YES

NO

Documents Reference

Does the production department only produce products that are declared and certified halal by JAKIM? Are there any consistency of the use of all material and additive? Are all materials recorded in the list of materials approved by JAKIM? If there is a product whose halal status is not yet clear (not halal certified), are the production equipment separated? Is there a possibility that a product which is not halal certified contain pork or its derivatives? If the products that are not halal certified by JAKIM do not contain pork or its derivatives, do sanitation procedures of production instrument conform to MUI rules and it’s the process supervised by IHC? If production tools of halal and not halal certified products are separated, is formulating room also separated? Are there no haram materials in the production area although they belong to another department or an individual? Are there no haram materials in the production although they belong to another department or an individual? Are all raw materials and additives systematically recorded and easily to be traced? Is the manufacture process done in such a way that it can avoid a product being contaminated by another product or material haram/najis? Does the production Department have working instruction for every stage of process?

Controlled Documents. © All rights reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission of company XYZ.

55

Halal checklist above show a series of methodically questioning on the HCP.

By

observing and answering those question, an auditor will be able to assess the implementation of the HAS system.

Question for the checklist must be based

upon the requirements contains in the MS1500:2009 as well as in the JAKIM Halal Manual Procedure. Only those item that has HCP potential need to be verified.

56

A. Halal Assurance System Manual Content

A halal Manual procedure consists of all these following elements. TABLE 4.3: HAS manual content NO

AREAS

DOCUMENTS AND CONTENT List of content

1

Document Control

Approval page List of manual distribution Amendment list Company Profile

2

Introduction

Implementation Objective Implementation scope

3

i.

Halal policy

ii.

Halal guidelines

iii.

Internal halal committee

iv.

Standard operating procedure

v.

Working Instructions

vi.

Administration system

Halal assurance

vii.

Documentation system

system

viii.

Socialization program

ix.

Training program

x.

Internal and external communication system

4

Appendices

xi.

Internal audit system

xii.

Corrective action system

xiii.

Management review system

Halal file

Examples of documents that should be made available in the HAS manual are shown on appendices sections. The exact content of these documentation are not binding to any requirements, statute, laws or directives. Nevertheless, what 57

is important here is that proper record where HAS is implemented and used can be found and referred to, when necessary. Different organization should adopt and create their own unique HAS documentation system.

58

CHAPTER HIGHLIGHTS At the end of this chapter, reader will be able to:

CHAPTER 5 INTERNAL HALAL AUDITING

T

he role of internal audit is to provide those responsible for governance with objective and

independent

assurance

on

the

effectiveness of halal processes. Fundamentally, this includes evaluating the effectiveness of controls on the whole range of halal and haram risks that the organization faces. This breadth of coverage enables halal internal audit to provide boards and audit committees with the information they need to satisfy themselves

that

all

key

halal

risks

are

being

effectively managed. Internal audit is one of the four cornerstones of good governance. As halal risk management takes center stage, internal audit’s unique perspective is becoming ever

59

 The importance of internal halal auditing  Understand on the requirement needed in halal auditing in terms of authority, scope of work and competent auditor.  Familiarize on the process flow of internal halal auditing  Know how to report on the audit finding  Understand the type of NCR and Corrective action request (CAR)

more valuable. In order to ensure that their halal risk management processes are properly integrated with no gaps in controls, internal audit is the only management function which can provide an overall view on an organization’s total risk management effectiveness. Boards, audit committees and executive management derive different benefits from the core functions of halal internal audit. They all want their organization to be more effective at delivering on its objectives for all its stakeholders. But each has a different perspective and as a result, the value they each extract from internal audit differs too [8]. Objectives of Internal Halal Audit

The objectives of the internal audit can be summarized as follows: 

To verify the correctness, accuracy and authenticity of the halal policies, procedure and implementation and presented it to the management.



To confirm that the non-conformances record have occurred in the organization in respect of its valid and legitimate activities.



To comment on the effectiveness of the halal internal control system and the internal halal check system in force and to suggest ways and means to improve these systems.



To facilitate the early detection and prevention of haram risk.



To identify the authorities responsible for NCR and rectification.



To ensure that the standard halal practices which have to be followed by the organization are strictly followed.



To undertake special investigation for the management.

60



To assist management in achieving the most efficient administration of the operation by establishing procedures by complying with company's operating policies.

Benefits of Internal Audit



Halal Internal audit feeds the managers with a perennial source of information for exercising effective control. By measuring performance, evaluating results and recommending suggestions for remedial actions, halal internal audit may be instrumental for forcing events to conform to plans.



The plan itself may be put to a critical study under an internal auditing Program so as to find out its appropriateness and effectiveness in the organization. Particularly, halal policies and procedures are appraised to see their relevancy and continuation towards the attainment of enterprise objectives. Briefly, halal internal audit may be utilized as the keeper of managerial conscience in the organization.



The introduction of a halal internal auditing program tones up the morale and working efforts of all members of the organization. The risk of being exposed before the eyes of- managers- induces persons to keep within the track and to avoid errors of omission or commission.



Internal audit scrutinizes halal production data to screen facts from the heaps of figures and statistics. Thus accounting for management information can be made to prevail under a program for halal internal audit.

61

Advantages of Halal Internal Audits 

The biggest advantage of halal internal audit is that it will lead to discovery of errors and therefore when external audit is done those errors which were discovered during internal audit would have been rectified by then.



Since halal internal audit is done by the employees of the company there is no additional cost involved which again is a big advantage for a company which is doing internal audit.



As halal internal audit is a constant procedure where records are checked regularly it ensures that accounting staff of a company keep the records up to date.

Disadvantages of Internal Audits 

Halal Internal audits report is not accepted by either the shareholders or tax authorities, it is the external auditor report which is required to be submitted to these parties.



Since halal internal audit is done by the employees of the company chances are that it may be biased and therefore company cannot depend on such reports.



Since a halal internal audit is not done by the professional auditor chances of internal auditor not detecting the errors are high.

a) Requirement i.

Authority In order to conduct internal halal committee (IHC), the management must delegate the authority to conduct the audit to the IHA team. This to 62

ensure smooth running of the auditing process, whereby it could involve several departments and the findings could have direct impact towards the halal integrity system, and the managerial aspect as a whole. The IHC team must be independent and free from any influences, even from the top management; otherwise it could not perform as it intended to be, to investigate the whole halal integrity system. Any direct influences could negate the outcome of the audit; therefore undermine the halal assurance system. ii.

Scope of work The IHC team’s scopes of work are limited to the area of halal integrity system, in all aspect of the supply chain; starting from procurement to the serving of food. They should be objective in doing their works by adhering to the task and must work within the parameter that they are given. The terms of reference will be based upon the Malaysian Standards MS series. For an example, IHA in a foodservice environment, the term of reference being used are the MS1500:2009 and JAKIM Manual Procedure. In these terms, the areas that are being audited including general and specific requirements are:



Documentation and company profile



Halal assurance system



Raw material / ingredients and processing aids



Packaging and labeling equipment



Storage



Production



Transportation 63

iii.



Employee



Sanitation system and premises cleanliness



Waste management



Premises physical condition

Competent Auditor Lead auditor In an auditing exercise, lead auditor play a vital role in determining the pace and outcome of the auditing process. To be a competent halal auditor is not an easy task as it takes some amount of responsibilities to make sure that the halal system integrities. A lead auditor must be Muslim who is technically competent with Shariah knowledge of halal principles. He or she must pose the necessary skills and experience to effectively perform the auditing. Minimum size for an audit team is 2 people.

Lead auditor function as the leader in a team. He or she must organize and manage the audit process and eventually make final decision regarding the outcome of the audit. Auditee then must facilitate the audit process by providing necessary resources and help with the audit. Auditor Meanwhile the auditor roles includes checking the current compliance status, identify non conformances, conduct follow up audit and lastly agreeing on suitable corrective action to remove non conformances record.

64

A halal auditor must pose these key competencies in order to perform as a good audit team. Auditor must:



Be qualified and trained in the audit process



Able to recognized halal, safety and quality criteria



Be Knowledgeable in halal codes of practice, legal requirements, industry guidelines and standards



Have skills in communications v. Able to identify and assess potential non halal issues

Like many other careers, to become a halal auditor, one must have selected personal attributes in order to be an effective auditor. Among the key personal attributes are:

FIGURE 5.1: Key Personal Attributes needed by an auditor

THOROUGH OBJECTIVES PUNCTUAL

OPEN MINDED PATIENT

OBSERVANT COMMUNICATOR

65

iv.

Auditing Process

Internal auditing is multi stages, multi-layer process. In HAS, internal halal auditing begins with a proper planning and preparation, and only after that the actual auditing can begin. FIGURE 5.2: Internal Halal Auditing Process

Audit Planning & Preparation Audit execution Adequacy audit

onsite audit

Audit report

Follow up Audit Closing Up audit Sources: [8]

66

Audit Planning & Preparation A good audit process must have an element of planning and preparation. It can be achieved by administering all these steps and procedure. Preamble of a good audit process should have a: Preparatory meeting During preparatory meeting, lead auditor and auditor as well as the Auditee must prepare and draft audit schedule or audit plans. During this meeting, it should be made clear regarding the purposes of the audit, personal affected, agendas for opening and closing meeting, attendance form, audit checklist and NCR forms. Auditing team should set a limit to their audit parameters to the scope of documentation,

workers,

raw

material

and

ingredients,

hygienic

factors,

premises, procedure, equipment, storage and packaging. Clear and define audit criteria The audit must be benchmarked against a set of predetermined set of standards, policies, procedures or requirements. It will be compared with the evidence collected. The standards will be using a reference standard for halal compliances. The standards are MS1500:2009 Halal Food production, preparation, handling & storage and JAKIM Manual procedure of Halal Certification Malaysia. Comprehensive checklist A checklist is a list that contains points/ elements for assessment and a tool often used and prepared by auditors for assessing the assurance of the halal products. It will ensure that every aspect of the elements and operation clearly defined and covered.

67

Audit Execution There are 2 types of audit used in halal auditing, which are the adequacy audit and compliance/on-site audit. Adequacy Audit Adequacy audit is an audit that evaluates all documentation in the HAS system. It includes documentation submitted for the purposes of applying halal certificate at JAKIM. It is also a desktop document audit which purposes are to: 

Examine the documents in the halal file.



Examine supportive documents for example product specification and halal certificate.



Verify that all elements of the MS1500:2009 and halal principle as required by Shariah law have been addressed.

The audit team during auditing process must be independent and free from any pressure of the management. They must take the roles as an external auditor to give a better perspective on the whole audit process.

68

FIGURE 5.3: Flow Chart of Adequacy Audit

Adequacy Audit Halal File, SOP and Procedure, Work Instruction, Halal Assurance System

Review of Documents

Completing Checklist Halal Audit Checklist

Preparing NCR Report Adequacy Audit Report

Compiling Audit Report

On-Site Audit Source: HDC Training Material

69

One key element in adequacy audit is the Halal file. Halal file is a requirement imposes by JAKIM during documentation inspection. Among the documents needed to be included in the halal file are: FIGURE 5.4: Content of Halal File

Registration of company/business

Halal certificate or product specification for critical ingredients

Process flow chart and production procedures

Company’s annual turnover

Manufacturing license from local authority

Copies of identity cards and offer letter for two Muslims at the production area, or cook at the food premise or checker for the slaughter house Slaughtering certificates for the slaughterer; (for slaughter house only) VSM certificate from Veterinary Department for slaughter house; (for slaughter house only) Manufacturing license from Cosmetic and drug Control Authority (for health products and cosmetic);

Design and label of products

Other documents such as HACCP, ISO, GHP, GMP, TQM and etc

Map of premises/factory location

70

Outcome of adequacy audit The outcome of the audit will be considered satisfactory only if all halal related documentation has adequately addressed the halal requirements or references standards. As opposed to this, unsatisfactory outcome includes:  Failure to addressed any procedure for halal compliances  Lack of a documents or records for halal compliances Compliance/ On Site Audit

The auditors will conduct on-site audit. The program will include entry (opening) meeting, plant visit, documentation comments, auditors meeting and exit (closing) meeting as shown in FIGURE 5.5 & FIGURE 5.8. If there are any Corrective Action Requests (CARs), the CARs will be presented during the exit meeting. The applicant will be given a certain period of time to rectify the type of non-conformance. This type of audit is an activity to obtain evidence that halal principle have been effectively applied and to ascertain full compliances with MS1500:2009 criteria and requirements. Objectives of this audit are to established conformity or non-conformity with agreed requirements on product and process.

71

STAGES IN COMPLIANCES/ ON SITE AUDIT FIGURE 5.5: Process flow of a typical audit (source: HDC training Material)

opening meeting

Conduct Audit Review Audit Finding Closing Meeting Compliance audit can only be commenced after the opening meeting. The audit must be conducted at the time of processing or the business are in motion and operational. At this part, an auditor must gather evidence objectively. How to gather evidence objectively? It can be done by examining documents and record, interviewing with designated personnel and through observation of practices and condition in the production area through onsite visit. Check for invoices for critical raw material as well as proof of Muslim workers by examining their identity cards, letter of appointment and training record. For hotel kitchen, the flow of workers could give some hints over the flow of material between halal and non halal structure such as storage and utensils.

72

During this visit, the auditor will assess management commitment in relation with: 

Halal policy



Internal halal committee



Halal executive



Internal halal audit



Communication on current issues and potential issues

Apart from that, they will also assess internal halal committee capability in terms of qualification, competencies (training record & experiences) and previous internal halal audit record. Lastly they will evaluate if all potential non halal issues have been considered and not allowing any non halal material in the premises such as customer bringing in their own alcoholic beverages and non halal food from home. An effective audit execution should has these following criteria such as: 

Concentrating on a particular process that has halal practices implication from beginning to end,



Cross interfaces between areas, functions or departments wherever they exist,



Visit all location,



Question directly the staff who actually carrying out the task,



Choosing a correct location,



Gathering sampling and evidence and Have a proper questioning technique.

73

Audit Checklist FIGURE 5.6 below clearly list out why checklist is considered a very important tool in an internal halal audit process. Apart from detailed questions and questioning techniques, checklist could help in speeding up the whole process.

FIGURE 5.6: The Importance of Checklist for an Auditor

Audit Checklist Will Provide And Help Auditor To:

Objective evidence that an audit was performed

The essence for the closing meeting and audit report

Act as references

Maintain the pace of the audit

Set in motion requirements to be met Identification of clauses in benchmark standards to be investigated Pre-prepared opening and closing meeting agenda

Furthermore, Checklists are important to asses some critical area in halal food production. Those areas are listed in below in FIGURE 5.7.

74

FIGURE 5.7: Critical areas need to covered in Internal Halal Auditing

HALAL EXECUTIVE INTERNAL HALAL COMMITTEE

ANIMAL BASED INGREDIENTS

SLAUGHTERER CERTIFICATE

CRITICAL AREAS IN AUDITING

MUSLIM WORKER/ HALAL CHECKER

HALAL ASSURANCE SYSTEM

INGREDIENTS AND PRODUCT SPECIFICATION IMPORT PERMIT

Opening Meeting Opening meeting is an essential part of any audit surveillance programs. It is done to explain to the Auditee exactly what the purpose of the audit is and how it is going to be carried out. During opening meeting, the chairperson must: 

Introduce the audit team to the Auditee



Circulate attendance roaster



Confirm audit schedule

75



Confirming the audit process and reference standards



Scope of the audit



Confirm the format of reporting

76

FIGURE 5.8: Sample of opening meeting agenda. (Halal Development Corporation)

Source: Halal Industry Development Corporation (HDC) Closing meeting At the end of the audit process a closing meeting or known as exit meeting must be held to present and discuss the finding of the audit. All relevant members should attend this meeting. It is a presentation of the audit findings and the

77

conclusion to the Auditee management to ensure that audit results are clearly understood. FIGURE 5.9: The Essence of Closing Meeting

Present the summary and audit team view of the organization halal compliance

Present the results & indicates what the strong points are

Present the non-conformances & agreed actions including corrective actions

78

FIGURE 5.10: Conducting a Closing Meeting

Lead auditor should circulate attendance list

Reconfirm scope of audit

Make clear that purposes of audit was to check for compliances

Should comment on any good aspect of the operation

State general impression/ position statement

Clarify that the findings is based on objective evidence presented

Obtaining signature of the auditee on the summary report form

Leaving copies of non-conformances report to auditee for further action

Arranging the nature & time scale for any required follow up audit

Closing remarks: thanking the auditee for the attention & cooperation given.

Review Audit findings

Towards the end of the auditing process, all of the auditor must crosscheck their finding and discus the implication and ramification of their report. At this point they shall: 

Discuss finding and observations

79



Determines if there is any non-conformances



Categories of non-conformances



Prepare corrective action request (CARs)



Prepare for closing meeting

b) Reporting

Audit Finding and Preparing Audit Report After the audit process has finished prepare a draft of audit report immediately and present it to the Auditee at the end of the audit. A report is a summary of audit findings and results and it’s provide information about the status of halal compliances. It must be produced after every compliances audit.

80

Content of the report should include these following items: FIGURE 5.11: Content of an audit report

Company names & address, dates of audit

Name of the auditors

Objective and scopes of the audit such as the name of areas, function or department visited and the processes audited

Audit summary

Reference documents

Total number of NCRs

Opening meeting/ exit meeting record of attendance and details of any problem arise

In the report also, this below item must be clearly reported and documented. The Results of the audit which covers: 

Position statement



Overall

evaluation

of

the

effectiveness

compliances 

Summary of NCR



The NCR clauses



The agreed corrective action to be taken

81

of

the

organization

halal



Agreed on follow up audit



Follow up action in terms of scope and timescale



Signatories of auditors and date

Copies of audit report should be made as be provided to the Auditee representative. If the audit found no such NCR the auditor and Auditee will sign off the compliance audit report during the closing meeting. c) Non-Conformances Record A non-conformance is an evidence of a failure or non-compliances of specified requirements as prerequisite in the standards. They are raised in the events of: 

unable to meet specified clauses and standards in the MS1500:2009 or any other standards



Not meeting a part of the procedure



Not meeting other recognized specification and regulation

Any non-conformances must be formally presented to the Auditee in order to initiate corrective actions. The normal approach is by raising the nonconformances report (NCR) which includes the followings: 

Date of the audit



Details of non-conformances



Clauses of the standards



Site or department audited



Auditee witnessing the non-conformances



A corrective action plan and date of completion of the non-conformances

82

NCR categories A NCR will be recorded whenever the auditor discovers that the halal requirements are inadequate or they are adequate but are not being followed correctly. There are 3 categories of NCR which are: FIGURE 5.12: Level of NCR

Non-Conformances Record (NCR)

SERIOUS

i.

MAJOR

MINOR

Serious

A serious NCR is an unacceptable or critical situation representing a non halal risk. Any serious rating requires immediate action responses and corrective action. This occurs in circumstances such as one of the ingredients has been found to contain pig’s derivative and the product contains alcoholic beverages such as wine. ii.

Major

This NCR deals with major or serious deficiencies which could lead to a non halal risk if not controlled. Any condition or situation rated as major requires a plan or program for rapid improvement, repetitive or cumulative major ratings can lead 83

to a serious situation such as utensils used for non halal can be samak only once or no segregation between halal and non halal product in storage area. iii.

Minor

Minor NCR is considered as excellent, good or only minor deficiencies (no non halal risk). Cleanliness and hygienic aspect are usually given the minor NCR.

84

CHAPTER HIGHLIGHTS

At the end of this chapter, reader will be able to:

CHAPTER 6 PRODUCT RECALL

P

roduct recall removes food that may pose a health or safety risk from distribution, sale and consumption. A food recall may occur

because

of

a

report

or

complaint

from

manufacturers, wholesalers, retailers, government and consumers. It may also occur as a result of a food

business

conducting

internal

testing

and

auditing. Food recalls can be at the trade or consumer level [12].

i.

Type of Product Recall

The class of recall is classified according to the seriousness of Halal risk and adverse effects of the products.

85

 Define what is Product recall  Types of product recall  Level of product recall

Class I: Products with major halal risks that might be present such as detection of non halal material in the product, processing and packaging. (Should be under an embargo within 24 hours). Class II: Products with minor/ unlikely halal risks or substandard quality in terms of Toyyiban aspects, and product defects not associated with halal risk. (Should be under an embargo within 72 hours). ii.

Level of Recall

The level of the recall depends on the nature of the problem, the extent of the product's distribution and the degree of halal risk involved. LEVEL A:

To all consumers (end users)

LEVEL B:

To all points of sales (e.g. retail shop, hypermarkets, restaurant etc.).

LEVEL C: iii.

To all sub distributors (wholesalers)

Dissemination of Product Recall Notices

Level A: To all consumers (end users) This level of recall will apply to all Class I recall and are carrying out in the comparatively rare instances when it is necessary to try to stop all use of a product and so to recover stock that has reached the end user. When there is imminent danger the public are warned by a media release which is meant to urgently alert the public by radio, television and the press. Level B: To all points of sale This level of recall will apply to Class II recall. All wholesalers will be identified and asked to provide contacted by telephone to obtain a list of all points of sale. These points can be established through a distribution record. Recall notices will

86

be mailed or faxed to all points of sales. At the same time representatives from the company will be sent to these points of sale to retrieve the stocks. Level C: To wholesalers and stockists This level of recall will apply to Class II recall where consumers are not at any risk from administering the products. The wholesalers and stockists will be contacted by the company representatives so that arrangement can be made to retrieve all stocks concerned from the wholesalers and stockists.

iv.

Product Recall Process

FIGURE 6.1 Steps in product recall Corrective action request Minor Serious

Major

Class II

Level B To all points of sale

CONSUMER LEVEL

Level C To wholesalers and stockists

DISTRIBUTOR/RETAIL ER

Class I

INTERNAL

Management review

Level A To all consumers (End users)

87

Product recall requires through planning and execution. Its main objective is to ensure the safety and well-being of consumer. Apart from that, product recall is one of the tools that can be used as public relation tools, maintaining consumer confidents in the products. The needs for products recall must be a valid one usually concerns with critical error and problems in the manufacturing process. As for foodservice operator that prepares and served food in-situ, product recall is not a major problem. Product can be easily taken out of the service line as well as display. Major concern is, notification to the end users as where it is next to impossible to trace back that has purchased the product. The Process starts when and after internal halal audit has been conducted. The outcome of the audit will categorized the NCR into 3, Serious, major and minor. FIGURE 6.1 defines how a product recall should be initiated. Only serious and major NCR will trigger a product recall. The process has been separated into 3 level which are at the internal, distributor/retailer and end user level. The management after being notified on the NCR, must classified the threat into Class I or Class II depending on the seriousness and gravity of the error. Company-wide control measure and corrective action must be taken immediately for both Class. Class I requires immediate action, usually within 24 hour after the problem has been identified. Embargo on selling the product should be announced directly to the consumer through media and product recall notification. Official statement from the company that contain this essential information:

88



Product Name



Batch Number



Nature of Recall ( reason for product recall)



Rectification program (where to returned, time frame, compensation for recall)



Contact number/ Hotline

In this class, retailer/wholesaler and all other point of sales should be notified and any remaining stock must be returned immediately to the manufacturer for disposal. The manufacturer could enlist the help of major retailer and wholesaler during rectification program. Class II are only meant for the distributor and retailer

89

CHAPTER HIGHLIGHTS

At the end of this chapter, reader will be able to:

CHAPTER 7 TRACEABILITY

T

raceability mechanism is established to trace default products so that action can be taken to identify and recall all suspected

products. Traceability is the ability to track any food through all stages of production, processing and distribution (including importation and at retail). Traceability should mean that movements can be traced one step backwards and one step forward at any point in the supply chain. Traceability enables corrective actions (such as a product recall) to be implemented quickly and effectively when something goes wrong. When a potential food safety problem is identified,

whether

by

a

food

business

or

a

government agency, an effective traceability system

90

 Define traceability in foodservice production and manufacturing of food.  Types of data in traceability

can help isolate and prevent contaminated products from reaching consumers. Traceability allows food businesses to target the product(s) affected by a food safety and halal problem, minimizing disruption to trade and any potential public health risks as well as haram risk. It is important for all food businesses (including retailers and importers) to be able to trace products. An effective traceability system relies on being able to track product one step forward and one step back at any point in the supply chain. The system a food business has in place includes any procedures for identifying producers, suppliers, customers and products and the records kept including: 

name and address (and other contact details) of suppliers and a description of products or inputs supplied



name and addresses (and other contact details) of customers and a description of the product supplied to them



date of transaction or delivery



batch or lot identification (or other markings)



volume or quantity of product supplied or received



Any other relevant production records.

Traceability in Halal Assurance System Proper HAS system should include a reliable traceability system. Each product sold must and can be traced back to the point of origin in terms of raw material, and can be detect in the distribution channels. A series of tools for traceability, by which “identification”, “link”, “records of information”, “collection and storage of information”, and “verification” are performed. The traceability system is composed of rules (promises and agreement) and procedures, documented

91

procedures, organizations/systems, and process and management resources (personnel, financial resources, machinery equipment, software, technologies and techniques), regulations and education / training. A traceability system can also use information system technologies for electronic data entry and database management services.

However, just having an

information system would not be sufficient to establish a traceability system. Also it is possible to construct a traceability system without using electronic information system databases. The halal traceability system is the system to prepare for accidents and nonconformity

regarding

halal

risk.

This

system

also

allows

verifying

correctness, in case the reliability of information carried in labels and the like, is at risk. It is

a direct measure to ensure halal and useful in obtaining the trust

of consumers and related food business operators. FIGURE 6.1: Key Areas in Traceability System

Materials

raw material packaging

Traceability

Documents manpower

92

Traceability system must be able to track 3 key component area in HAS system which are the materials flow, documents and manpower. For each ingredients used, the raw material must be able to be trace and finished products can be detected to a certain point in time through batch or lot allocation. Not only that, the person or parties responsible for that particular action must also be traceable. Documents must be stored and archive systematically to ensure the integrity of the HAS system. Documents, when required for auditing purposes, are available at the moment notices. Each process flow, material must be documented in facilitating the traceability system. Apart from that, processes owner, as well as the employee who were given the task must be identified. Each employee must be given a specific task or responsibilities so that any error in the processing can be determined to the exact point. This also vital to ensure that no unwanted personnel to be present during the production process.

93

Steps in Halal Traceability

   

Animal feed Fertilizer seeds Manufacturing practices

Transporter Warehousing

Raw Materials Additives Other Ingredients Packaging.

TRANSPORTATION

Receiving

PRE PRODUCTION

FIGURE 6.2 Traceability overview within an organization

PRODUCTION

Production Packaging

Packaging

Wholesaler

Retailer

POST PRODUCTION

TRANSPORTATION

Consumer

Figure 6.2 illustrates the traceability programs for a company start from the source of the material. The traceability program is divided into 3 separate area and time-link, Pre production, production and post-production.

94

Each time-link process needs to be monitored and recorded. Material received in the premises must be able to be tracked back to its origin. Tracing tools such as barcode, delivery order and invoice must be check and recheck with prevalent specification set by the companies. If the supplier using third party logistic services, the delivery order should also include the vehicle information as well as the time stamp and dates. Most of the logistic company has an integrated tracking system that track the shipment whereabouts as well as the time they start shipping out the material. At the production level

95

APPENDICES

HAS MANUAL CONTENT & TEMPLATE

96

LIST OF CONTENT NO

AREAS

DOCUMENTS AND CONTENT List of content

1

Document Control

Approval page List of manual distribution Amendment list Company Profile

2

Introduction

Implementation Objective Implementation scope Halal policy Halal guidelines Internal halal committee Standard operating procedure

3

Halal assurance system

Working Instruction Halal Critical Point Administration system Documentation system Training program Internal audit system Management review system

4

Appendices

Halal file

97

PAGE

Distribution List

DEPARTMENTS

IHC

DATE OF IMPLEMENTATION

PROCESS OWNER

Head of IHC

VERSION

1 January 2016 HAS/MAN/VC-01-2016 (01-20)

HALAL ASSURANCE SYSTEM (HAS) MANUAL PREPARED BY INTERNAL HALAL COMMITTEE OF COMPANY XYZ APPROVED AND VERIFIED TO BE USED

--------------------------------------------------------(AHMAD SAHIR JAIS) CEO, Company XYZ Controlled Documents. © All rights reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission of company XYZ.

Approval Page

98

HAS MANUAL DISTRIBUTION LIST NO DEPARTMENT

NAME

SIGNATURE

DATE

Documents #

HAS/MAN/VC-012016 (01-20) HAS/MAN/VC-012016 (02-20) HAS/MAN/VC-012016 (03-20) HAS/MAN/VC-012016 (04-20)

1

CEO Office

Ahmad Sahir

sahir

1/1/2016

2

General Manager Purchasing

Faizal

Faizal

1/1/2016

Salleh

Salleh

1/1/2016

Hisham

Hisham

1/1/2016

3 4

Internal Halal Committee

5

Controlled Documents. © All rights reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission of company XYZ.

Distribution List

99

DEPARTMENTS PROCESS OWNER

IHC Head of Committee

DATE OF IMPLEMENTATION DOCUMENT REFERENCES

1 January 2016 HAS/MANUAL/AMMLIST/01-2016

AMENDED LIST

CHANGES NO

1

DATE

12.12.2016

AMENDMENT VERSION

HAS/MANUAL/012016

REVISED DOCUMENTS

CHAPTER

PAGE

VERSION

HAS/MANUAL/012016 (Rev 1/2016)

7

CHAPTER

PAGE

7

REMARKS Changes in IHC structure

Controlled Documents. © All rights reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission of company XYZ. Amended List

100

Company Profile

DEPARTMENTS

IHC

PROCESS OWNER

Head of Committee

DATE OF IMPLEMENTATION DOCUMENT REFERENCES

1 January 2016 HAS/MANUAL/COMPROF/012016

COMPANY PROFILE Company Background Company XYZ a public limited company listed on the Main Market of BURSA MALAYSIA on the 20 October 1994. Its core business activities are in the mass production of basic daily necessities fresh table and specialty chicken eggs, liquid egg, chilled and frozen dressed chicken, chicken parts and processed related chicken products eg. Frankfurters, nuggets, fried chicken etc. We are also contract packed specialized chicken cuts and chicken related products for certain fast food chain. The group's products are marketed under two registered brands namely Nutriplus and Wise Choice. Financial

Our Product

Board of Director Dato’ Dr. Abdul Aziz Bin Jais Independent Non-Executive Chairman Yap Hong Chong Group Managing Director Non-Independent Executive Director Heap Wing sang Non-Independent Executive Director Yap Cher kun Non-Independent Executive Director Ng Kim toing Non-Independent Executive Director year Feck Chai Non-Independent Non-Executive Director

101

Implementation Objectives

DEPARTMENTS

IHC

PROCESS OWNER

Head of Committee

DATE OF IMPLEMENTATION DOCUMENT REFERENCES

1 January 2016 HAS/MANUAL/IMPOBJ/012016

IMPLEMENTATION OBJECTIVES The objectives of Company XYZ Halal Assurance Management System are the following: 1. To ensure the integrity of Halal processing by continuously and consistently monitored on the compliance to the Shariah (Islamic Law). 2. To ensure compliance to all guidelines issued by Malaysian authorities such as Halal Assurance Management System of Malaysia Halal Certification produced by Department of Islamic Development Malaysia (JAKIM). 3. To ensure compliance to the Malaysia Standard MS 1500:2009 Halal Food Production, Preparation, Handling and Storage – General Guideline (Second Revision) produced by SIRIM.

Controlled Documents. © All rights reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission of company XYZ.

102

Implementation Scope

DEPARTMENTS

IHC

PROCESS OWNER

Head of Committee

DATE OF IMPLEMENTATION DOCUMENT REFERENCES

1 January 2016 HAS/MANUAL/IMPSCOPE/012016

IMPLEMENTATION SCOPE The halal assurance system (HAS) are specially designed for company XYZ. HAS system covers all, but not limited to entire aspect of the production areas. Scope of the HAS system covers: 

Product development process



Purchasing process



Storage process



Production process



Transportation process



Display, serving and merchandising process

The scope of this HAS is limited within the confinement listed in MS1500:2009 - Halal Food Production, Preparation, Handling And Storage - General Guidelines (Second Revision), “Manual Prosedur Pensijilan Halal Malaysia 2014 (Semakan Ketiga),” Pekeliling Pensijilan Halal Malaysia Bilangan 2 Tahun 2014, Jabatan Kemajuan Islam Malaysia and “Guidelines For Halal Assurance Management System Of Malaysia Halal Certification.” Halal Hub Division, Department Of Islamic Development Malaysia Guidelines, Kuala Lumpur,

Implementation is conducted across the board in XYZ Company including the suppliers and third party service provider.

Controlled Documents. © All rights reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission of company XYZ.

103

DEPARTMENTS

IHC

PROCESS OWNER

Head of Committee

DATE OF IMPLEMENTATION DOCUMENT REFERENCES

1 January 2016 HAS/MANUAL/HALPOLICY/012016 Halal Policy

COMPANY XYZ HALAL POLICY Company XYZ is committed to providing first class through setting quality objectives and targets in all areas of our operation including food delivery with respect to halal and food safety with the aim of continually improving our service performance. Our performance is regularly monitored and measured and the results, used by management to deliver improved customer services. Consistent with our approach to achieving sustainable outcomes, we are committed to complying with and exceeding, where practicable, relevant Malaysian halal and food safety legislation and other related requirements as set by JAKIM. Company XYZ is committed to complying with the requirements of our halal assurance, food safety and quality management system and to working with our customers, suppliers, contractors and employees to continually improve its effectiveness. Company XYZ is committed to meet the halal regulatory requirements by ensuring that the ingredients that we use are certified by the authorized halal certification bodies and other related regulatory bodies, and that our processing aids, equipment and utensils are clean and free of nonhalal ingredients. A Halal committee, comprising representatives from various departments, has been established with responsibility for all matters pertaining to halal regularities. Company XYZ will work to ensure our quality policy is communicated maintained and distributed to our customers, suppliers, contractors and employees and is subject to periodic review to ensure its continued suitability.

Ahmad Sahir Jais Chief Executive Officer Company XYZ

104

DEPARTMENTS

IHC

PROCESS OWNER

Head of Committee

DATE OF IMPLEMENTATION DOCUMENT REFERENCES

1 January 2016 HAS/MANUAL/HALGUIDE/012016 Halal Guidelines

HALAL GUIDELINES A. Preface In this part principle of halal and haram in Al Qur’an and Fatwa from JAKIM will be described. Sources of Islamic Law: 1. Al Qur’an. It is The Holly Book of Islam. It contains philosophy, principles, and theories of Islamic laws which are work of Allah for the guidance of mankind. It mainly prescribes permanent, absolute, values and basic principles of Islamic laws. 2. Al-Hadis. It is the authentic practice of Prophet Muhammad (the saying, actions, habits, and approvals) that explain in detail the application of the Qur’an principles. 3. Ijma Sahabat. It is the consensus of the opinion of the sahabat (companions of the prophet Muhammad based on their understanding of The Al Qur’an and Al Hadis). 4. Qiyas. It is a law making method by comparing thing with cases already explained in Al Qur’an and Al Hadis. 5. Fatwa. It is Islamic legal opinion about law status of a certain case made by Ulama (Islamic Scholars).

B. Meaning of Halal Haram 1. Halal means lawful. In the case of food, most are halal except for some that are explicitly mentioned in the Al Qur’an or Hadiths. 2. Haram is something prohibited by God Almighty. People who deliberately ignore what is not allowed will face God’s punishment in the life hereafter. Some even face Islamic law sanctions in life.

C. Principles on Halal and Haram Status 1. 2. 3. 4. 5.

Everything is halal unless explicitly forbidden Only Allah has the right to legislate for man Prohibiting halal and permitting haram is unlawful Haram is always associated with what is bad and harmful There is always a better substitute in halal for that which is haram 105

6. 7. 8. 9.

Anything that leads to haram is considered haram It is haram to declare something halal when it is manifestly haram Good intensions do not justify committing haram One should guard oneself against matters that are on the borderline between halal and haram 10. In extreme circumstances, haram is permissible within certain limits.

Continued…….

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106

DEPARTMENTS PROCESS OWNER

IHC Head of Committee

DATE OF IMPLEMENTATION DOCUMENT REFERENCES

1 January 2016 HAS/MANUAL/IHC/01-2016

INTERNAL HALAL COMMITTEE of COMPANY XYZ

AHMAD SAHIR JAIS , CEO

JEFFRY DIN, Head of IHC

NANCY WONG SEW YOKE, Secretary

LATIFF IBRAHIM

DAHLAN ZAINUDIN

MD NOOR

SANTHA VELLU

Operations/ Production

Procurement

Technical / QA / QC

R&D

Internal Halal Committee

107

INTERNAL HALAL COMMITTEE IHC Head of Committee

DATE OF IMPLEMENTATION DOCUMENT REFERENCES

Creating, implementing and monitoring HAS

POLICY MAKER

TOP LEVEL MANAGEMENT

DEPARTMENTS PROCESS OWNER

Documentation and Record Keeping

Operational Compliances. Application and monitoring of HAS

Operations/ Production Procurement Head of Committee

Secretary Technical / QA / QC R&D

108

1 January 2016 HAS/MANUAL/IHC (2)/01-2016

DEPARTMENTS IHC PROCESS OWNER

Head of Committee

DATE OF 1 January 2016 IMPLEMENTATION DOCUMENT HAS/MANUAL/MGMTREV/01REFERENCES 2016 Management Review System

MANAGEMENT REVIEW SYSTEM

AUDIT REPORTS

ASSES MANAGERIAL EFFECTIVESNESS

CONDUCT AUDIT

MONITOR CONTROL MEASURES & CORRECTIVE ACTIONS

  

MONITOR NCR

Management Review of the HAS system must be conducted annually, corresponding with Internal halal auditing. Details of the review must be documented and kept in HAS Manual Each signatories must sign at the documents acknowledging that the review has been conducted.

109

Halal Assurance System (HAS) – STANDARD OPERATING PROCEDURE DEPARTMENTS

Purchasing and Procurement Dept.

DATE OF IMPLEMENTATION

1 January 2016

PROCESS OWNER

Purchasing Manager

VERSION

HAS/MANUAL/SOP-PP/01-2016

DESCRIPTION

TASK

5. Material purchased should conform to the list approved by JAKIM 6. Material purchased must conform to data mentioned in the halal certification documents. Check For : d) Bill of material e) Product Specification sheets f) Product code and SKU # 7. Check for Transportation (Vehicle Cleanliness, Not using transport which has been used to carry haram products. 8. Purchasing documents must be well documented (Delivery Order, Purchase request, Invoice etc.)

Purchasing Manager & Receiving Officer

Receiving Clerk & Production Manager

Purchasing Manager & Receiving Officer Purchasing Clerk & Finance Department

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Standard Operating Procedure – SOP

110

Halal Assurance System (HAS) – STANDARD OPERATING PROCEDURE DEPARTMENTS

Production

DATE OF IMPLEMENTATION

1 January 2016

PROCESS OWNER

Line Manager

VERSION

HAS/MANUAL/SOP-PROD/012016

DESCRIPTION

TASK

1. Production work sheet should refer to formula and matrix of material approved by JAKIM 2. Materials that can be used in halal production should refer to the list of raw material approved by JAKIM and having been given a halal Certificate. 3. Production line should be used for halal materials only. 4. Materials should be free from contamination by anything that is najis and haram. 5. If production line is used for materials that have not been given halal certificate then cleaning procedure should be done properly to prevent cross contamination. 6. If non certified products containing pork derivatives are present, the equipment and production lines must be separated. 7. Materials not used in production are strictly prohibited to be located in the production.

Line Manager, Line Supervisor, Purchasing Manager Line Manager, Line Supervisor, Purchasing Manager Line Manager & Line Supervisor

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111

Halal Assurance System (HAS) – WORKING INSTRUCTIONS DEPARTMENTS

Production

DATE OF IMPLEMENTATION

1 January 2016

PROCESS OWNER

Line Supervisor

VERSION

HAS/MANUAL/WINST-PROD/012016

DESCRIPTION

TASK

1. At the mixing station, please check the following before beginning of the process: a) Material name on the packaging, expiration date, condition of the item. b) Record item tracking number for ingredients such as their batch and lot number 2. Begin with adding the least critical item first according to this sequence. b) Water c) Salt d) Palm oil e) Yeast f) Bread improver g) flour 3. Begin mixing under specified time and condition. Mixing vessel should not be opened to prevent contamination from foreign material 4. Take sample and the end of the process. Record and noted before sending to QC/ QA

Line Supervisor & Production Staff

Line Supervisor & Production Staff

Line Supervisor & Production Staff Line Supervisor & Production Staff

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Working Instruction

112

PROCESS FLOW & HALAL CRITICAL POINT

DEPARTMENTS PROCESS OWNER

IHC Head of Committee

DATE OF IMPLEMENTATION DOCUMENT REFERENCES

Cooling

Procurement

HCP

Receiving

Baking

Inspection

Production line

1 January 2016 HAS/MANUAL/HCP -01/01-2016

Packaging

Distribution

HCP

HCP Storage

Material Request

Halal Critical Point (HCP)

113

114

PROCESS FLOW & HALAL CRITICAL POINT DEPARTMENTS

Production

PROCESS OWNER

Line Manager

DATE OF IMPLEMENTATION DOCUMENT REFERENCES

1 January 2016

HAS/MANUAL/HCP -PROD/01-2016

RAW MATERIAL Flour, Yeast, Salt, Water, Bread Improver, Palm oil

HCP 1

MIXING

DOUGH MAKING

PROOFING

HCP 2

PORTIONING

PAN GREASE

DEPOSITS IN PAN

BAKING AND SLICING

HCP 3

PACKAGING AND LABELING

Stearate anti sticking agent

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115

DEPARTMENTS

Purchasing & Procurement

PROCESS OWNER

P & P Manager

DATE OF IMPLEMENTATION DOCUMENT REFERENCES

1 January 2016

HAS/MANUAL/HCP –PP/01-2016

Product Specification

Supplier Submit Product Specs

HCP 1

Check For halal Certificate

HCP 2

NO YES

Purchase List HALAL TRANSPORTATION

YES HCP 3

Receiving

NO NO

Comparing With Products Specs

YES

REJECT SHIPMENTS

HCP 4

Storing

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116

Control Measure & Corrective Action DEPARTMENTS PROCESS OWNER

Production Line Manager

NAME MATERIAL

DATE OF IMPLEMENTATION VERSION

HCP

Control Measure

1 January 2016 HAS/HCP-CAM/PROD-01-2016

CORRECTIVE ACTION

VERIFICATION

DOCUMENTATION

NO. Bread Improver

Grease Pan / Oleo Resin

Contains lecithin

Contain Stearate, from animal product

 Product Specification must be clear on the type and point of origins of the material  Proven halal certificate  Reputable and Known Brand  Recheck material packaging with the BOM  Product Specification must be clear on the type and point of origins of the material  Proven halal certificate  Reputable and Known Brand



  



  

Rejects if information on packaging does not correspond with halal certification Check for packaging integrity, no repack item be accepted Reject all batches if has been tainted Initiated line shutdown



Rejects if information on packaging does not correspond with halal Certification Check for packaging integrity, no repack item be accepted Reject all batches if has been tainted Initiated line shutdown







Check during receiving by receiving clerk Check by line supervisor at mixing station

Product specification

Check during receiving by receiving clerk Check by line supervisor at depositing station

Product specification

Receiving SOP

Receiving SOP

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117

Administration System

DEPARTMENTS IHC PROCESS OWNER

Head of Committee

DATE OF 1 January 2016 IMPLEMENTATION DOCUMENT HAS/MANUAL/ADMIN/01REFERENCES 2016

ADMINISTRATION SYSTEM NO 1

DEPARTMENT / SECTION Purchasing

2

QA/QC

3 4 5

Production Sales & Marketing Logistic

FUNCTION All documents for procurements must be documented and signed accordingly. Purchasing must ensure that every product conform to the specification set. Any changes in the products specification must be communicated to the head of IHC immediately through verbal and written comunicae. Conduct periodical inspection on the quality and halal assurance on the raw material and finished material before leaving the production area. Used rapid detection kit for porcine on random sample prior leaving the factory premises.

118

COMPANY XYZ HALAL INTERNAL COMMITTEE – MINUTES OF MEETING DATE

1/1/2016

Prepared By Name & signatures Verified By Name & signatures

NO

DISCUSSION

1

The CEO welcomes all committee member and wishes good luck them on the appointment as IHC. CEO hands over meeting to Head of IHC, Mr. Faizal

2

Mr. Faizal announces that HAS Manual must be distributed to all level immediately.

TIME

12.45 pm

VENUE

CEO Office

ATTENDEES

List attached

DOCUMENT REFERENCES

HAS/MANUAL/MINUTES (01) /01-2016

OUTCOME (SET DATE & TARGET) NC

NC

6th January 2016

Department head

ACTION

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IHC meeting minutes

119

HALAL ASSURANCE SYSTEM – COMPANY XYZ

Annual Halal Training Program Schedule and Implementation DEPARTMENTS IHC PROCESS OWNER

NO. 1

Head of Committee

TIME / DATE / PLACE 12th January

DATE OF 1 January 2016 IMPLEMENTATION DOCUMENT HAS/MANUAL/TRAIN/01REFERENCES 2016

PARTICIPANTS

2016

Production Department.

10.30 PM /

Name List attached.

MEETING ROOM

Training Given by IHC

TOPIC

Halal awareness. Halal Critical Control point.

1 2

7th March 2016.

Purchasing Department.

8.30 AM.

Name List attached.

Loading bay

Training Given by IHC

3 th

5

may 2016

Briefing and training on new ingredients

QA/QC. Name List

Implementation on new

attached. Training Given

on-the-spot porcine

by IHC

detection kit.

4

Halal Training

120

HALAL SOCIALIZATION PROGRAM DEPARTMENTS PROCESS OWNER

IHC Head of Committee

DATE OF IMPLEMENTATION DOCUMENT REFERENCES HALAL SOCIALIZATION PROGRAM

1 January 2016 HAS/MANUAL/HALSOC/01-2016

STAKEHOLDER STRATEGIES

THE MANAGEMENT

EMPLOYEE

SUPPLIER

CONSUMER

Familiarization

The management shall introduced a comprehensive halal program

Each employee will undergo a minimum 6 hours training on halal prior to the implementation of HAS

Supplier of existing material will be brief on the new requirement. New supplier will be asked to abide by the new product specification.

Consumer will be notified in advanced on the ongoing halal certification process

Induction

The management shall draft and provide all the necessary resources prior to implementing the HAS system

Each Employee will be given hands on training on how to use and manage HAS system at the operational level. Simulation will be used to access the readiness level.

Existing supplier will be given ample to conform to the new HAS. IHC will assess the readiness level of supplier to conform with HAS

Changes will be made to existing product such as phasing out product that does not conform with the new HAS for example new packaging material and so on

Implementation

The Management team must be knowledgeable on the halal assurance system

SOP and Working instruction must be available to every employee and must be adopted as a routine.

The general public will be made aware of the company halal policies. Consumer will be able to participated in giving feedback on the product as well as the halal assurance system

Every 6 month

Refresher course every 6 month with full internal halal auditing annually.

Product specification must be met by the supplier without any discrepancies. Disregards to the HAS will results in termination of contract. Supplier will be brief and audited periodically. Refresher course every 6 month with full internal halal auditing annually.

Refresher Course

Halal Socialization Program

121

DEPARTMENTS IHC PROCESS OWNER

Head of Committee

DATE OF IMPLEMENTATION DOCUMENT REFERENCES

1 January 2016 HAS/MANUAL/IHASYSTEM /01-2016 Internal Halal Audit System

INTERNAL HALAL AUDIT SYSTEM

Audit Planning & Preparation Audit execution Adequacy audit

onsite audit

Audit report

Follow up Audit Closing Up audit

122

HALAL INTERNAL AUDIT CHECKLIST DATE : TIME : PERSON IN CHARGE : DOCUMENT REFERENCE

23 Nov 2015 10.30 pm Faizal

LOCATION AUDITOR

Production Line 1 Baharom

HAS/MANUAL/IHA-CHKLIST/01-2016 ( 1 ) Prepared By:

Verified by:

Acknowledge by:

baharom

santha

faizal Halal audit Checklist

Department/ Process Flow : refer to HAS/MANUAL/HCP -PROD/01-2016 Requirement in standards : MS1500:2009, JMP (3rd) RESULTS OF AUDIT NO. QUESTION YES NO 1 2 3 4

5

6

7

8

9

10

11

12

Documents Reference

Does the production department only produce products that are declared and certified halal by JAKIM? Are there any consistency of the use of all material and additive? Are all materials recorded in the list of materials approved by JAKIM? If there is a product whose halal status is not yet clear (not halal certified), are the production equipment separated? Is there a possibility that a product which is not halal certified contain pork or its derivatives? If the products that are not halal certified by JAKIM do not contain pork or its derivatives, do sanitation procedures of production instrument conform to MUI rules and it’s the process supervised by IHC? If production tools of halal and not halal certified products are separated, is formulating room also separated? Are there no haram materials in the production area although they belong to another department or an individual? Are there no haram materials in the production although they belong to another department or an individual? Are all raw materials and additives systematically recorded and easily to be traced? Is the manufacture process done in such a way that it can avoid a product being contaminated by another product or material haram/najis? Does the production Department have working instruction for every stage of process?

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123

NON-CONFORMITY RECORD (NCR) REPORTS This report need to be attached with the Internal Halal Audit Checklist if any NCR incidents to Occur. One (1) Copy per incidents. DATE : TIME : PERSON IN CHARGE : DOCUMENT REFERENCE

23 Nov 2015 LOCATION 10.30 pm AUDITOR : Faizal HAS/MANUAL/IHA-NCRREPT/01-2016 ( 1 ) Prepared By: Verified by: baharom santha

Production Line 1 Baharom

Acknowledge by: faizal Non-Conformity Record (NCR) Reports

NO

NCR INCIDENTS / DETAILS DESCRIPTION One of the sacks containing bread improver has been found to be different from the original specification in terms of packaging at the mixing station. Initiating investigation with purchasing to find whether the material used are the same. Description

1

Evidence : refer to HAS/MANUAL/IHA-CHKLIST/01-2016 ( 1 )

REMARKS Purchasing has been Notified QA/QC has taken sample for porcine detection using rapid test kit.

No Porcine detected using rapid detection kit

FINDINGS OF NON-CONFORMITY The material is the same. Only changes with the packaging. Supplier didn’t notified purchasing dept. in advance

Level of NCR

2

CAUSE ANALYSIS

Process Flow Error Type

( ) Minor ( / ) Serious ( ) Major HAS/HCP/PROD-01-2016 HAS/HCP/PP-01-2016 ( ) Mechanical

124

Cc to Purchasing Dept. Notification to suppliers

Late Notification. No Haram risk

NO

NCR INCIDENTS / DETAILS DESCRIPTION

Action Taken 3

CORRECTIVE ACTIONS REQUESTs (CAR’S) Status Due Date Requested By Verified By

REMARKS

( / ) Human ( ) Others. Please Specified

detected

( / ) Immediately ( / ) Time specific (2nd December 2015)

Production lines were stop and continued after clarification from the material supplier. Suppliers sent a new Material specification indicating changes in packaging material.

Supplier are warned to give ample notice before committing to any changes in their products Corrected 2nd Dec 2015 baharom santha

In the case of NCR Level Major, Total Shutdown of the production line must be initiated. IHC must be notified immediately.

125

REFERENCES [1]

Halal Hub Division Department of Islamic Developtment, “Guidelines For Halal Assurance Management System Of Malaysia Halal Certification.” Halal Hub Division, DEPARTMENT OF ISLAMIC DEVELOPMENT MALAYSIA GUIDELINES, Kuala Lumpur, 2012.

[2]

Department of Standards Malaysia, MS1500:2009 - Halal Food Production, Preparation, Handling And Storage - General Guidelines (Second Revision). 2009.

[3]

Kementerian Kesihatan Malaysia, AKTA MAKANAN 1983 - PERATURANPERATURAN KEBERSIHAN MAKANAN 2009. 2009, pp. 1–60.

[4]

Bahagian Hub Halal, “Manual Prosedur Pensijilan Halal Malaysia 2014 (Semakan Ketiga),” PEKELILING PENSIJILAN HALAL MALAYSIA BILANGAN 2 TAHUN 2014. Jabatan Kemajuan Islam Malaysia, 2014.

[5]

H. Abdul Talib, K. A. Mohd Ali, and K. R. Jamaludin, “Quality Assurance in Halal Food Manufacturing in Malaysia : A Preliminary Study,” in Proceedings of International Conference on Mechanical & Manufacturing Engineering, 2008.

[6]

Jabatan Kemajuan Islam Malaysia, “FREQUENTLY ASKED QUESTIONS ABOUT MALAYSIAN HALAL CERTIFICATION.” [Online]. Available: http://www.asianfoodreg.com/dynamicAssets/regulationDoc/1411655242_ HalalFAQ.pdf. [Accessed: 04-Nov-2015].

[7]

“Halal - Certification Flow.” [Online]. Available: http://www.halal.gov.my/v4/index.php/en/pensijilan-halal/carta-alirpensijilan. [Accessed: 04-Nov-2015].

[8]

Ahmad Sahir Jais, HALAL PRACTICES IN FOODSERVICE OPERATION, 2nd ed. Sabak Bernam Selangor: Politeknik Sultan Idris Shah, 2011.

[9]

Department of Standards Malaysia., MS 2424:2012 Halal Pharmaceuticals General Guidelines. Malaysia, 2012.

[10] Muhamad Nadratuzzaman Hosen, “General Guidelines Of Halal Assurance System.” TThe Assessment Institute For Foods, Drugs And Cosmetics, Indonesian Council Of Ulama (LPPOM MUI), Jakarta, 2008. [11] M. N. Riaz and M. M. Chaudry, Halal Food Production. Boca Raton: CRC Press, 2004. [12] Zurina Shafii and Siti Noradibah Zain, “Halal Assurance Mechanisms in Halal Industry : an Appraisal on Its Effectiveness Towards Continuous Halal Assurance and the Way Forward,” in International Conference on Education and Social sciences, 2015, no. February, pp. 1430–1438.

126

Ahmad Sahir Jais is a Lecturer / head of Program for Diploma in Foodservice (Halal Practice) in Politeknik Merlimau Melaka. With 12 Years of teaching experience, he specialize in Foodservice Management, culinary and Halal training. He is also a certified Halal Trainer recognized by the Halal Development Corporation (HDC).