Journal of Tea Science Research. 2015, Vol. 5, No. 6, 1-14
7
such as employee involvement, management support
and continuous focus element, within organization
have a greater impact to quality management
development and implementation (Fredendall et al.,
2006). Thus organizations with objective of
implementing 5S in their workplaces must have a
culture of considering learning as a fundamental
requirement of survival of an organization (Pool,
2000; Nikolic and Nastasic, 2010).
Furthermore, concept of quality circle approach had
a great influence to 5S applications in tea industry;
in which workers banded as small teams working in
specific areas for the betterment and smoothness of
operation where cleaning, organizing and managing
workplace was more efficient with them. According
to Swinton (2004) and Isoeasy (2006), the formation
of quality teams within the organizations had helped
to carryout quality assurance process while contributing
to the continual sustainability of the organization’s
performance over long run. Designing a properly
documented management system was not an easy
task, because it has to consider various aspects
before finalizing a given set of instructions or
preparing a record for evidencing the systematic
approach as well as following the exact system
guidelines. On the other hand, designing was the key
activity in transforming key strategies, requirements
and techniques selected for the system where digital
or paper based systems have to draft all the manuals,
policies, objectives, scope, procedures, prerequisite
programs, work instructions, standard operating
procedures, records, reports and checklists etc.
considering the ISO 22000 FSMS and tea manufac-
turing. It was mandatory to prepare food safety
procedures, prerequisite programs, HACCP plans
and OPRP plans with work instructions for various
operational requirements as well as records for the
evidence which was necessary for auditing purposes;
were systematically evaluated.
The documentation pyramid was considered as the
cornerstone for the documentation developments,
where the first tire (Figure 02) was consist of ISO
22000 policy statement, scope, objectives and the
manual (manual is optional) . The second tire was
Figure 2 Documentation Pyramid
consisted of food safety procedures and prerequisite
programs where hazard analysis also came under
same layer. However, the 3
rd
layer was basically
used for work instruction where ISO 22000 and 5S
requirements were consolidated in to single set of
instructions while considering to use available 5S
practices with alignment to ISO 22000 requirements.
The 4
th
layer of the documentation pyramid
normally consisted of records, reports, checklists
and any kind of evidencing documents which were
basically keep for the auditing purposes and for the
traceability requirements.
Considering the given requirements, work instructions
were written in following order, where it was
basically to educate operators or labourers in case of
they don’t know what is tea manufacturing or a
specific operation. In such situations, the work
instruction booklets are given to relevant person for
reading in order to raise his/her knowledge on the
specific process and then he may be start the work
under the supervision of the relevant supervisor or
another senior worker. However, the work instruction
has great deal of information on the exact work
where employee will have the opportunity of
understanding standard operating procedure of a
given operation, its cleaning requirements, specific
methods of cleaning and the way it must be visible
