Supply chain constraints are not a new challenge in the food industry. Food is a global market, and even the smallest food processor brings in food ingredients, packaging, and equipment from around the world. Included in this article are tips and tricks for managing inventory, supplier, and warehouse challenges for food manufacturing facilities.

Ensuring that non-conforming product is never created—or at least never arrives at customers' doorsteps—is invaluable in the food industry. Reduced downgrade, less rework, and decreased out-of-specification product are all benefits of mistake proofing.

Food processing facilities experience many different changeovers. Rapid changeover, or Single-Minute Exchange of Die, can be beneficial to increasing efficiencies in a food processing facility. Reduction in downgrade or defects and an increase in employee communication and morale are several benefits of a well-oiled changeover process.

Many methods are available for verifying the viability of a sanitation program, and most facilities use a combination of different methods to ensure that the sanitation program is performing as expected. Pathogen environmental monitoring (PEM) programs are a key prerequisite program to a sanitation program and to any facility's overall food safety program. There is no one-size-fits-all PEM program for facilities; rather, a PEM program is based on a facility's risk factors and what product(s) the facility manufactures.

If you look around, you may find many examples of ‘TIM WOODS' in your facility. TIM WOODS is an acronym for the ‘eight wastes' that can plague a processing facility. In lean manufacturing, waste is any cost, effort, or material that is used in a processing facility that does not directly lead to a completed unit.

The culture of a facility in food safety or customer relations is impacted by how customer communications are managed. Customer complaint trending and response are part of a company or facility's risk management strategy. The objective of any management system is to try to protect the company from adverse actions. Understanding and responding to customer complaints is one strategy.

Food safety and quality systems do not have to be cumbersome and difficult to follow. The 5S system, when launched and properly maintained, can have a positive impact on food safety and quality programs, as well as operational efficiency.

Used food processing equipment can be a great asset to a facility, but it is important to ensure that the equipment will fit with existing processing needs and food safety considerations.