Journal of Tea Science Research. 2015, Vol. 5, No. 6, 1-14
13
as 5S requirements which reduced the time
spent for recordings on two systems.
Synchronization further reduced the number of
documents used in the system up to a great
extent as well as frequency of recording while
improving the effectiveness of recording.
Nevertheless, work instructions were written
based on 5S work instructions developed in tea
industry because there were no extraordinary
differences in writing work instruction for a
given work since it was the instructions provided
for a specific operation. Thus 5S work
instructions were enriched with food hygiene
requirements instead of developing new set of
instructions where harmonization and modification
was much easier than any other areas of ISO
22000:2005.
Cleaning and housekeeping were also added to the
work instruction which further enhance the utility
of the work instruction since cleaning schedules
were also a set of instruction for a specific cleaning
operation amalgamate to the relevant machinery,
equipment and processing area. All the cleaning
schedule requirements were properly synchronized
with ISO 22000 as well as 5S. The evidences or
records were also greatly adapted to the given
requirements in specific places where checklists
were easily understandable and applicable to the
specific locations.
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.
The changes in the mode of recording in
preventive maintenance reduce the huge time
required for unnecessary data entries while
improving the actual application of the record.
Nevertheless, cleanliness and orderliness of
machines as well as equipments and utensils
were added to the cleaning checklist instead of
mentioning areas without proper specifications
which gave an additional advantage of verifying
the individual hygiene and cleaning of each
machine in the factory. The cleaning work
instructions were further enriched with
individual standards for each and every work
carried out where it was easier for the QA officer
to verify the cleaning and sanitation program on
visual observation and verify it or rectify any
errors or mistakes spotted.
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