RBI Food Quality Systems Audit

Supplier Information
Facility Name PT Foodindo Dwivestamas Facility ID 64495
Facility Address Industri Selatan IV Street - Blok GG-5G BKC Region Indonesia
Industri Jababeka II, Estate - Pasirsari
Cikarang-Bekasi-Indonesia, Jakarta Raya,
Indonesia
Facility Contact Tjia Mei Liang
Corporate Name PT Foodindo Dwivestamas Corporate
ID
BK Approved Mushroom Sauce
Specifications

Audit Score
Total Points 1005 Percent 0% Maximum 1235
Deduction Points
Reasons for Percent Deduction No penalty
Score (%) 81.38 Audit Grade Red Pass/Fail Fail

# of Criticals 1

Audit Details
Audit Start Date 20-SEP-2017 Audit End Date 20-SEP- Date of Last Audit
08:55:00 AM 2017
07:00:00 PM
Auditor Name Ni Putu Eni Kartika Dewi Audit reference # 1705720
Key Facility Afrianal (Manager Production) Vita Riswanti (RnD staff) Sumba S. (QA Staff) Dewi
Members Indriani (HR) Tiur (purchasing) Sylvia (RnD Manager) Tini ( Manager QA and QC)
present during
the audit
Audit Summary
A Restaurant Brands International, Inc. (RBI) Quality Systems Audit was conducted at your facility on the
above date, the audit was part of your ongoing obligation to meet RBI Supply Quality Assurance
requirements and maintain Approved Supplier Status to the RBI restaurant system. I would like to thank
everyone for their time and participation during the audit. The scope of the audit was Mushroom Sauce
from raw ingredients receipt to finished product dispatch, including the ancillary / common areas of the
process and the exterior of the facility. Additionally, a mock recall traceability exercise formed part of the
audit.
The facility currently operates 2 shifts, 6 days per week with approximately 140 employees and has a total
site area of 4500 m2. There is 2 production lines and 1 of these lines are used to manufacture Restaurant
Brands International, Inc. products.
The audit findings were reviewed during the audit and discussed with you in the Closing Meeting and are
detailed in this RBI Quality Systems Audit Report. Please review the audit report findings and be aware
that all non-conformances set out in this report must be corrected in order to maintain the facility's
Approved Supplier Status with Restaurant Brands International, Inc.
Please put your Corrective Action Plan onto NSF Online at https://clients.nsf.org/ within 5 business days of
receiving this RBI Quality Systems Audit Report. If your company's Corrective Action Plan is not submitted
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 RBI Food Quality Systems Audit

on NSF Online within 5 business days, this will affect your company's status on the RBI Supplier Database
and you will be contacted by the RBI APAC Corporate Supply Quality Assurance Team to upload your
Corrective Action Plan.
I again thank you for your time and hospitality during my visit and for your commitment to the Burger King
brand. If you have any questions on this RBI Quality Systems Audit Report please do not hesitate to email
the auditor.

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 RBI Food Quality Systems Audit

Critical Failures
Question # Finding
Q16 Found cockroaches in production areas which been the NC since last audit. Detail as
section 14.
3 cockroaches in equipment box ( found gear gear and cutting in that box) in cutting area.
2 cockroaches inside empty freezer box in warehouse.
2 cockroaches inside employee locker.
2 cockroaches inside equipment box in the cutting area.
2 cockroaches on floor in the CCP 1 -cooking area.
3 cockroaches in the CCP 3 – Sealing area.
1 cockroach in the employee locker room.

Also critical finding the direct contact with the ingredient, 2 cockroaches inside ingredients
container of the starch corn in the CCP 1 -cooking area.

Audit Non Conformances Summary

Question # Finding
Q2 i2.5 Are allergens adequately separated from the non-allergens in storage areas?
Allergen finished product and non allergen were not separated in chiller room. Facility
put them in the same room and on the same rack without labels between allergen and
non allergen for finished product.
i2.7 Are utensils used for allergen containing ingredients properly segregated or
cleaned?
Utensils in weighing area used to weigh ingredients were not labeled for allergen and
non allergen product.

Q3 i3.5 Are corrective actions taken based on the conclusions of mock recovery exercises?
Found 1 exercise for BK that did not have summary conclusion, but all document was
fully in compliance .

Q4 i4.1 Are all minor non-conformances in GFSI audit corrected/part of a formal corrective
action?
NO GFSI audit in facility
i4.2 Are all major non-conformances in GFSI audit corrected/part of a formal corrective
action?
NO GFSI audit in facility

Q5 i5.2 Are all findings in latest RBI audit corrected?

Non-conformances that were not corrected:
1. Cutting board in cutting area was heavily scratched as previous finding.
2. Still found ingredients that were not covered when not in process. Observed chopped
garlic in area CCP 1 (cooking) was not cover and inside container was placed by spray
bottle alcohol.
3. Still found cockroach in production area.
4. Still found door was not fitting closed in warehouse and production area.
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Q7 i7.1 Receiving: Is this area in Conformance with RBI QA or industry standards?

1. Auditor observed gaps under the door in receiving area which had direct access into
ingredients warehouse.
2. Found garbage bin was broken in receiving area.

Q8 i8.1 Production: Is this area in Conformance with RBI QA or industry standards?

1. Observed broken floor in cooking area.
2. Cutting board was heavily scratched in receiving area.
3. Found 1 broken container used for finished product.
4. Door was not fitting closed in production area, the door has access from outside into
production area.
5. Open ink inside container and put with ingredients corn starch.
6. Soap without label in CPP 2 (Filling into Plastic bag).
7. Observed cooking oil in cleaning area without label. Facility mentioned that oil was
unused.
8. Kapur bagus was stored in shoe rack inside laboratory area.
9. Found broken rack in lab, facility uses that rack to store documents.
10. Food grade oil was not separated, but was placed with non food grade oil in
maintenance area.
11. Found broken scissor in equipment box inside cooking area.

i8.2 Production: Further to i8.1, does this area have instances of minor non-conformance
with RBI QA or industry standards?
1. Observed broken floor in cooking area.
2. Cutting board was heavily scratched in receiving area.
3. Found 1 broken container used for finished product.
4. Door was not fitting closed in production area, the door has access from outside into
production area.
5. Open ink inside container and put with ingredients corn starch.
6. Soap without label in CPP 2 (Filling into Plastic bag).
7. Observed cooking oil in cleaning area without label. Facility mentioned that oil was
unused.
8. Kapur bagus was stored in shoe rack inside laboratory area.
9. Found broken rack in lab, facility uses that rack to store documents.
10. Food grade oil was not separated, but was placed with non food grade oil in
maintenance area.
11. Found broken scissor in equipment box inside cooking area.

i8.3 Production: Further to i8.1, does this area have any major non-conformance with
RBI QA or industry standards?

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Auditor found employee drinking bottle that was put on ice container. The ice was use to
cooling down sauce product.

Q9 i9.1 Warehouse/Storages/Freezers/Coolers: Is this area in Conformance with RBI QA or

industry standards?
1. Broken floor in storage in front of chiller area.
2. Found dirty freezer box in warehouse, facility did not use it anymore but it was not
labeled that the equipment was unused.
3. Rack to store finished product in chiller was dirty.
4. Dirty floor in chiller floor, many unused products and garbage below the rack for
finished product.
5. Found some broken product that was stored with and on finished product in chiller.
Facility did not separated the area for finished product and broken product.

Q10 i10.1 Changing rooms, Canteen Area and Corridors or rooms leading to production
areas: Is this area in Conformance with RBI QA or industry standards?
1, Door not fitting closed in production room.
2. Found unused equipment stored under stair in production area.
3. Maintenance room inside production area was not well organized, many unused
equipment stored and many debris and dirty. Maintenance room is located in production
area in front of changing room.

Q13 i13.1 Is the facility in conformance to GMPs (RBI QA and general industry standards)?
Found team member was cleaning facility and doing manual task of squeezing dirty
towel and then would come into cooking area and touch air curtain without washing hand
before entry to cooking area.

Q14 i14.1 Are production and storage areas of Facility free of pest activity?
Auditor found some live cockroach and dead cockroach:

Live cockroach :
3 cockroach in equipment box ( found gear gear and cutting in that box) in cutting area
2 cockroach inside container ingredients for starch corn product in area CCP 1
(cooking area)
2 cockroach inside empty freezer box in warehouse
2 cockroach inside employee locker.

Dead Cockroach:
2 cockroach Inside equipment box in cutting area,
2 cockroach in floor area CCP 1 (cooking area)
3 cockroach in area CCP 3 Sealing
1 cockroach in employee locker room

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i14.2 Further to i14.1, what level of pest activity was noted in the production and storage
areas of Facility?
Auditor found some live cockroach and dead cockroach:

Live cockroach :
3 cockroach in equipment box ( found gear gear and cutting in that box) in cutting area
2 cockroach inside container ingredients for starch corn product in area CCP 1
(cooking area)
2 cockroach inside empty freezer box in warehouse
2 cockroach inside employee locker.

Dead Cockroach:
2 cockroach Inside equipment box in cutting area,
2 cockroach in floor area CCP 1 (cooking area)
3 cockroach in area CCP 3 Sealing
1 cockroach in employee locker room

Q15 i15.1 Is this Sanitation Program in production areas in conformance?

1. Chemical in mineral bottle without label in cutting area.
2. Cleaning supply was stored in cutting area when not in use, there was dirty water
placed in that cleaning equipment.
3. Chlorine concentration was lower than 50 ppm in foot bath production area.

Q16 i16.1 No product contamination was observed, during the audit?

Product Contamination – Critical finding as there is direct contact with the ingredient, 2
cockroaches inside ingredients container of the starch corn in the CCP 1 -cooking area.
i16.2 Further to i16.1, product contamination WAS observed during the course of the
audit.
Product Contamination – Critical finding the direct contact with the ingredient, 2
cockroaches inside ingredients container of the starch corn in the CCP 1 -cooking area.

Q17 i17.1 Is the supplier able to access RBI Brands Specification system?
Facility not able to access into RBI SPEQ system, but latest spec was available in
facility.

Q18 i18.1 Is the actual supplier formulation in compliance with RBI specification?
Actual formulation was not same with spec system formulation as below:
1. Actual formulation for unsalted butter was 8.72%, Speq formulation was 9.17%
2. Actual formulation for Wheat flour was 4.47% and Speq Formulation was 4.4%
3. Actual formulation for Nabati Cooking oil was 1.07% and speq formulation was 0.25%

i18.2 Further to i18.1, was there one instance of non-compliance with RBI specification?
Actual formulation was not same with spec system formulation as below:
1. Actual formulation for unsalted butter was 8.72%, Speq formulation was 9.17%
2. Actual formulation for Wheat flour was 4.47% and Speq Formulation was 4.4%
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3. Actual formulation for Nabati Cooking oil was 1.07% and speq formulation was 0.25%

i18.3 Further to i18.2, were there two or less instances of non-compliance with RBI
specification?
Actual formulation was not same with spec system formulation as below:
1. Actual formulation for unsalted butter was 8.72%, Speq formulation was 9.17%
2. Actual formulation for Wheat flour was 4.47% and Speq Formulation was 4.4%
3. Actual formulation for Nabati Cooking oil was 1.07% and speq formulation was 0.25%

Q22 i22.1 Are all instances of out of specification situations in processing quality control
records, properly corrected?
Quality control points for Chemical Type value BRIX in BK product was 18%. However
refer to spec max brix should be 15%.
i22.3 Are the non-conforming in process products properly identified and segregated?
Broken product was placed in same chiller with BK finish product and not managed well.
Facility does not separate the chiller for non conforming product. Found some open
containers filled with nonconforming product in chiller area.

Q24 i24.1 Are all Chemical finished product control records in compliance with the
specification?
Quality control point for section chemical finished product criteria Brix was not same as
spec, according to spec maximum brix should be 15%, however range actual for brix in
facility was 15-20%.

Q26 i26.2 Is the outer packaging for all products inspected according to specification?
Specification minimum for outer packaging was 0.38 KG, however actual weigh for outer
packaging for BK was 0,375 KG.

Facility - Documentation, Product Safety and Control Max Possible Score: 225

Q1 HACCP: CCP's are defined, documented and enforced.

Comments: Facility has 4 CCP for BK product: Actual points: 75
1. CCP 1 : Cooking tempt with critical limit for product
should be >85'C
2. CCP 2: Filling temperature with critical limit
temperature product should be >70'C
3. CCP 3: Sealing machine temperature with critical
limit for machine temperature shoulde be>180
4. CCP 4: Metal machine with metal pieces FE 1,5mm,
Non Fe 2mm, Sus 2,5 mm
This is a critical failure question. If the question score is not 50 points or more, the
Alert! audit will be automatically failed. If the score is over 50 points, but there are critical
flaws in the processes covered by the question, which may endanger the food safety
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control over the RBI Brands products, the audit will also be failed.
i1.1 Is there a well-defined and properly trained HACCP team? Yes: 5 Points
i1.2 Is the HACCP coordinator HACCP certified? Yes: 5 Points
i1.3 Are there appropriate pre-requisite programs in place to ensure an environment Yes: 5 Points
suitable to produce safe food and are they included in the HACCP?
i1.4 Does the HACCP plan include a proper product description, covering intended Yes: 5 Points
use?
i1.5 Does the HACCP plan include a process flow chart outlining each step involved in Yes: 5 Points
the process?
i1.6 Is there a valid hazard analysis document that properly covers each product? Yes: 10 Points
i1.7 Are proper CCPs in place to eliminate or minimize all hazards identified? Yes: 10 Points
i1.8 Have critical limits and operating limits been defined for each CCP? Yes: 5 Points
i1.9 Are there defined and documented monitoring procedures for each CCP? Yes: 5 Points
i1.10 Are there documented corrective actions to be taken for each CCP? Yes: 5 Points
i1.11 Have verification procedures demonstrated the HACCP plan is effective? Yes: 5 Points
i1.12 Does the HACCP plan include a product contamination prevention plan? Yes: 5 Points
i1.13 Is there an adequate measurement equipment calibration program in place? Yes: 5 Points

Q2 Allergen Program: Functional documented program.

Comments: Allergen system setup in ingredients warehouse. They Actual points: 40
separated rack and area for allergen and non allergen
ingredient.
i2.1 Does the supplier have a documented Allergen Control Program? Yes: 10 Points
i2.2 Are allergens part of the HACCP program? Yes: 10 Points
i2.3 Is the production schedule organized in such a way to prevent cross contact of Yes: 5 Points
allergens?
i2.4 Is the rework on allergen containing ingredients properly handled regarding Yes: 5 Points
allergen control?
i2.5 Are allergens adequately separated from the non-allergens in storage areas? No
Allergen finished product and non allergen were not separated in chiller room. Facility
put them in the same room and on the same rack without labels between allergen and
non allergen for finished product.
i2.6 Are allergens adequately labeled in storage areas? Yes: 5 Points
i2.7 Are utensils used for allergen containing ingredients properly segregated or No
cleaned?
Utensils in weighing area used to weigh ingredients were not labeled for allergen and
non allergen product.
i2.8 Is the staff adequately trained on allergens and allergen control policies and Yes: 5 Points
procedures?

Q3 Product Traceability: Ingredient usage and rework is adequately documented by lot numbers to
support 100% lot traceability.
Comments: Facility able to finish traceability within 2 hours. Actual points: 20
i3.1 Is supplier able to complete a forward mock recovery exercise of finish products in Yes: 5 Points
2 hours?
i3.2 Is supplier able to complete a backward mock recovery exercise of raw materials Yes: 5 Points
in 2 hours?
i3.3 Does the supplier have a documented product recall and recovery program? Yes: 5 Points
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i3.4 Is the supplier doing mock recovery exercises according to RBI standard? Yes: 5 Points
i3.5 Are corrective actions taken based on the conclusions of mock recovery No
exercises?
Found 1 exercise for BK that did not have summary conclusion, but all document was
fully in compliance .

Q4 RBI GFSI Audit Review: Adequate actions have been taken to address non-compliant and
partially compliant deficiencies.
Comments: NO GFSI audit in facility Actual points: 0
i4.1 Are all minor non-conformances in GFSI audit corrected/part of a formal corrective No
action?
NO GFSI audit in facility
i4.2 Are all major non-conformances in GFSI audit corrected/part of a formal corrective No
action?
NO GFSI audit in facility

Q5 RBI Actions Points Review: Adequate follow up given to deficiencies from previous audits, RBI
Complaints and/or other RBI communication.
Comments: No customer complaints from RBI during period 2016- Actual points: 15
2017. Facility already has analysis complaint from other
customer.
i5.1 Was the corrective action report for the latest RBI audit, approved in time (30 Yes: 5 Points
days)?
i5.2 Are all findings in latest RBI audit corrected? No
Non-conformances that were not corrected:
1. Cutting board in cutting area was heavily scratched as previous finding.
2. Still found ingredients that were not covered when not in process. Observed
chopped garlic in area CCP 1 (cooking) was not cover and inside container was
placed by spray bottle alcohol.
3. Still found cockroach in production area.
4. Still found door was not fitting closed in warehouse and production area.
i5.3 Does supplier perform analysis on RBI customer complaints? Yes: 5 Points
i5.4 Does supplier respond to RBI customer complaints within the required time? Yes: 5 Points

Q6 Control of Offsite storage and contracted Transport.

Comments: No off site storage or contracted transport in facility for Actual points: 25
BK product.
i6.1 Are offsite storage facilities properly controlled by the supplier? Yes: 10 Points
i6.2 Are contracted transport vehicles properly controlled by the supplier? Yes: 10 Points
i6.3 Are contracted transport vehicles temperatures properly controlled by the Yes: 5 Points
supplier?

Facility - Physical Plant Max Possible Score: 280

Q7 Plant Walk Through: Receiving

Comments: Supplier receiving facility meet RBI industry standard. Actual points: 10
There is a system for raw materials and supplier
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approval program and incoming materials verification

process is in accordance with industrial standard.
i7.1 Receiving: Is this area in Conformance with RBI QA or industry standards? No, there were
1. Auditor observed gaps under the door in receiving area which had direct access into instances of non-
ingredients warehouse. conformance
2. Found garbage bin was broken in receiving area.
i7.2 Receiving: Further to i7.1, does this area have instances of minor or major non- Minor instances
conformance with RBI QA or industry standards? were identified:
1. Auditor observed gaps under the door in receiving area which had direct access into 10 Points
ingredients warehouse.
2. Found garbage bin was broken in receiving area.

Q8 Plant Walk Through: Production

Comments: Observed both minor and 1 major instances in Actual points: 40
production area that did not meet RBI requirements for
building structure and also cleanliness. However,
process control program and facility requirements meet
RBI standard.
i8.1 Production: Is this area in Conformance with RBI QA or industry standards? No, there were
1. Observed broken floor in cooking area. instances of non-
2. Cutting board was heavily scratched in receiving area. conformances
3. Found 1 broken container used for finished product.
4. Door was not fitting closed in production area, the door has access from outside into
production area.
5. Open ink inside container and put with ingredients corn starch.
6. Soap without label in CPP 2 (Filling into Plastic bag).
7. Observed cooking oil in cleaning area without label. Facility mentioned that oil was
unused.
8. Kapur bagus was stored in shoe rack inside laboratory area.
9. Found broken rack in lab, facility uses that rack to store documents.
10. Food grade oil was not separated, but was placed with non food grade oil in
maintenance area.
11. Found broken scissor in equipment box inside cooking area.

i8.2 Production: Further to i8.1, does this area have instances of minor non- Two or more
conformance with RBI QA or industry standards? minor instances
1. Observed broken floor in cooking area. were identified
2. Cutting board was heavily scratched in receiving area.
3. Found 1 broken container used for finished product.
4. Door was not fitting closed in production area, the door has access from outside into
production area.
5. Open ink inside container and put with ingredients corn starch.
6. Soap without label in CPP 2 (Filling into Plastic bag).
7. Observed cooking oil in cleaning area without label. Facility mentioned that oil was
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unused.
8. Kapur bagus was stored in shoe rack inside laboratory area.
9. Found broken rack in lab, facility uses that rack to store documents.
10. Food grade oil was not separated, but was placed with non food grade oil in
maintenance area.
11. Found broken scissor in equipment box inside cooking area.

i8.3 Production: Further to i8.1, does this area have any major non-conformance with There were major
RBI QA or industry standards? instances of non-
Auditor found employee drinking bottle that was put on ice container. The ice was use conformance
to cooling down sauce product. identified

i8.4 Production: Further to i8.3, does this area have major instances of non- One major
conformance with RBI QA or industry standards? instance
Auditor found employee drinking bottle that was put on ice container. The ice was use identified: 40
to cooling down sauce product. points

Q9 Plant Walk Through: Warehouse/Storages/Freezers/Coolers

Comments: Some instance identified in warehouse area that not Actual points: 10
meet RBI standard such as building structure and
garbage around chiller area.
i9.1 Warehouse/Storages/Freezers/Coolers: Is this area in Conformance with RBI QA No, there were
or industry standards? instances of non-
1. Broken floor in storage in front of chiller area. conformance
2. Found dirty freezer box in warehouse, facility did not use it anymore but it was not
labeled that the equipment was unused.
3. Rack to store finished product in chiller was dirty.
4. Dirty floor in chiller floor, many unused products and garbage below the rack for
finished product.
5. Found some broken product that was stored with and on finished product in chiller.
Facility did not separated the area for finished product and broken product.
i9.2 Warehouse/Storages/Freezers/Coolers: Further to i9.1, does this area have Minor instances
instances of minor or major non-conformance with RBI QA or industry standards? were identified:
1. Broken floor in storage in front of chiller area. 10 Points
2. Found dirty freezer box in warehouse, facility did not use it anymore but it was not
labeled that the equipment was unused.
3. Rack to store finished product in chiller was dirty.
4. Dirty floor in chiller floor, many unused products and garbage below the rack for
finished product.
5. Found some broken product that was stored with and on finished product in chiller.
Facility did not separated the area for finished product and broken product.

Q10 Plant Walk Through: Changing rooms, Canteen Area and Corridors or rooms leading to
production areas
Comments: Found some minor instance in changing room and Actual points: 5
corridor room, however facility have good standard that
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require with RBI standards.

i10.1 Changing rooms, Canteen Area and Corridors or rooms leading to production No, there were
areas: Is this area in Conformance with RBI QA or industry standards? instances of non-
1, Door not fitting closed in production room. conformance
2. Found unused equipment stored under stair in production area.
3. Maintenance room inside production area was not well organized, many unused
equipment stored and many debris and dirty. Maintenance room is located in
production area in front of changing room.
i10.2 Changing rooms, Canteen Area and Corridors or rooms leading to production Minor instances
areas: Further to i10.1, does this area have instances of minor or major non- were identified: 5
conformance with RBI QA or industry standards? Points
1, Door not fitting closed in production room

2. Found unused equipment stored under stair in production area

3. . Maintenance room inside production area was not well organize, many unused
equipment stored and many debris and dirty. maintenance room located in production
area in front of changing room.

Q11 Plant Walk Through: Shipping

Comments: Operation facility in packing, shipping, handling and Actual points: 10
storage in facility was clean and meets industry
standard.
11.1 Shipping: Is this area in Conformance with RBI QA or industry standards? Yes, area is in full
compliance: 5
Points
i11.2 Shipping: Further to i11.1, does this area have instances of minor or major non- N/A: 5 Points
conformance with RBI QA or industry standards?

Q12 Plant Walk Through: Outside perimeter and Security

Comments: Outside parameter and security area was compliance Actual points: 10
with RBI industry standard. facility have a good system
especially for security system.
i12.1 Outside perimeter and Security: Is this area in Conformance with RBI QA or Yes, area is in full
industry standards? compliance: 5
Points
i12.2 Outside perimeter and Security: Further to i12.1, does this area have instances N/A: 5 Points
of minor or major non-conformance with RBI QA or industry standards?

Q13 GMPs
Comments: Supplier facilities, vehicles, methods, and controls used Actual points: 25
in manufacturing, handling, storing, and transporting
product in facility are operating according to a GMP
program accordance with the RBI Supplier Quality
Assurance Program. Facility has establish training
program to all department and GMP system meets RBI
standard industry.
Non-conformance was noted in this area.
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i13.1 Is the facility in conformance to GMPs (RBI QA and general industry standards)? No, there were
Found team member was cleaning facility and doing manual task of squeezing dirty instances of non-
towel and then would come into cooking area and touch air curtain without washing conformance
hand before entry to cooking area.
i13.2 Further to i13.1, does the area have instances of non-conformance to GMPs Minor instances
(RBI QA and general industry standards)? identified with
facility GMPs: 15
Points
i13.3 Further to i13.2, does this area have major instances of non-conformance to N/A: 10 Points
GMPs (RBI QA and industry standards)?

Q14 Pest Control

Comments: Found dead and live cockroaches in production area Actual points: 5
also in changing room.
i14.1 Are production and storage areas of Facility free of pest activity? No, there were
Auditor found some live cockroach and dead cockroach: instanes of non-
conformance
Live cockroach :
3 cockroach in equipment box ( found gear gear and cutting in that box) in cutting
area
2 cockroach inside container ingredients for starch corn product in area CCP 1
(cooking area)
2 cockroach inside empty freezer box in warehouse
2 cockroach inside employee locker.

Dead Cockroach:
2 cockroach Inside equipment box in cutting area,
2 cockroach in floor area CCP 1 (cooking area)
3 cockroach in area CCP 3 Sealing
1 cockroach in employee locker room

i14.2 Further to i14.1, what level of pest activity was noted in the production and Three or more
storage areas of Facility? instances of
Auditor found some live cockroach and dead cockroach: nonconformance
were identified
Live cockroach :
3 cockroach in equipment box ( found gear gear and cutting in that box) in cutting
area
2 cockroach inside container ingredients for starch corn product in area CCP 1
(cooking area)
2 cockroach inside empty freezer box in warehouse
2 cockroach inside employee locker.

Dead Cockroach:
2 cockroach Inside equipment box in cutting area,
2 cockroach in floor area CCP 1 (cooking area)
3 cockroach in area CCP 3 Sealing
1 cockroach in employee locker room
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i14.3 Is the pest control program in the Facility in conformance? Yes: 5 Points

Q15 Sanitation
Comments: Sanitation program was in conformance with RBI Actual points: 55
industry standards.
i15.1 Is this Sanitation Program in production areas in conformance? No, there were
1. Chemical in mineral bottle without label in cutting area. instances of non-
2. Cleaning supply was stored in cutting area when not in use, there was dirty water conformance
placed in that cleaning equipment.
3. Chlorine concentration was lower than 50 ppm in foot bath production area.
i15.2 Further to i15.1, does Sanitation have instances of non-conformance with RBI Only minor
QA or industry standards? instances of
1. Chemical in mineral bottle without label in cutting area. nonconformance
2. Cleaning supply was stored in cutting area when not in use, there was dirty water identified: 20
placed in that cleaning equipment. Points
3. Chlorine concentration was lower than 50 ppm in foot bath production area.
i15.3 Is the Sanitation Program in non-production areas in conformance? Yes, Sanitation
Programs are in
full compliance: 5
Points
i15.4 Further to i15.3, does Sanitation have instances of non-conformance with RBI N/A: 10 Points
QA or industry standards?
i15.5 Does the Supplier have a monitoring program to verify sanitation of the Yes: 10 points
manufacturing environments?
i15.6 Does the Supplier cleanliness verification routinely include an objective Yes: 10 points
measurement?

Q16 Observed Product Contamination

Comments: Found cockroaches in production areas which been the Actual points: 0
NC since last audit. Detail as section 14.
3 cockroaches in equipment box ( found gear gear and
cutting in that box) in cutting area.
2 cockroaches inside empty freezer box in warehouse.
2 cockroaches inside employee locker.
2 cockroaches inside equipment box in the cutting area.
2 cockroaches on floor in the CCP 1 -cooking area.
3 cockroaches in the CCP 3 – Sealing area.
1 cockroach in the employee locker room.

Also critical finding the direct contact with the

ingredient, 2 cockroaches inside ingredients container
of the starch corn in the CCP 1 -cooking area.
This is a critical failure question. If the question score is not 10 points or more, the
audit will be automatically failed. If the score is 10 points, but there are critical flaws
Alert!
in the processes covered by the question, which may endanger the food safety
control over the RBI Brands products, the audit will also be failed.
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i16.1 No product contamination was observed, during the audit? Instances of

Product Contamination – Critical finding as there is direct contact with the ingredient, 2 product
cockroaches inside ingredients container of the starch corn in the CCP 1 -cooking contamination
area. WERE observed
i16.2 Further to i16.1, product contamination WAS observed during the course of the Instances of
audit. product
Product Contamination – Critical finding the direct contact with the ingredient, 2 contamination
cockroaches inside ingredients container of the starch corn in the CCP 1 -cooking were identified
area. but were NOT
corrected

Product Max Possible Score: 730

Q17 Current specification is available and is in use.

Comments: Facility not able to access into RBI SPEQ system, but Actual points: 40
latest spec was available in facility.
i17.1 Is the supplier able to access RBI Brands Specification system? No
Facility not able to access into RBI SPEQ system, but latest spec was available in
facility.
i17.2 Does the facility have all RBI specifications for their approved products Yes: 10 Points
available?
i17.3 Does the facility have the latest version of each RBI specification? Yes: 10 Points
i17.4 Is the facility's quality system specification matched to the latest RBI specification Yes: 10 Points
available?
i17.5 Does the supplier update RBI on any changes affecting the specifications? Yes: 10 Points

Q18 Product formulation matches the specification.

Comments: Some formulations were not the same between in spec Actual points: 30
and actual formulation in facility.
i18.1 Is the actual supplier formulation in compliance with RBI specification? No, there were
Actual formulation was not same with spec system formulation as below: instances of
1. Actual formulation for unsalted butter was 8.72%, Speq formulation was 9.17% nonconformance
2. Actual formulation for Wheat flour was 4.47% and Speq Formulation was 4.4%
3. Actual formulation for Nabati Cooking oil was 1.07% and speq formulation was
0.25%

i18.2 Further to i18.1, was there one instance of non-compliance with RBI There was more
specification? than one
Actual formulation was not same with spec system formulation as below: nonconformance
1. Actual formulation for unsalted butter was 8.72%, Speq formulation was 9.17% instance
2. Actual formulation for Wheat flour was 4.47% and Speq Formulation was 4.4%
3. Actual formulation for Nabati Cooking oil was 1.07% and speq formulation was
0.25%

i18.3 Further to i18.2, were there two or less instances of non-compliance with RBI There were more
specification? than two
Actual formulation was not same with spec system formulation as below: instances of

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 RBI Food Quality Systems Audit

1. Actual formulation for unsalted butter was 8.72%, Speq formulation was 9.17% nonconformance
2. Actual formulation for Wheat flour was 4.47% and Speq Formulation was 4.4% identified
3. Actual formulation for Nabati Cooking oil was 1.07% and speq formulation was
0.25%

i18.4 Further to i18.3, were there more than three instances of noncompliance with Three or less
RBI specification? instances of
nonconformance
identified: 30
Points

Q19 Controlled ingredients are used as specified.

Comments: Control ingredients in facility area used as specified, Actual points: 30
they control all raw material and process control until
finish product
i19.1 Are Raw Materials used in compliance with Raw Material Specifications? Yes: 10 Points
i19.2 Are CIFs used in compliance with CIF Specifications? Yes: 10 Points
i19.3 Are Subformulations used in compliance with Subformulation Specifications? Yes: 10 Points

Q20 COAs are on file for ingredients, as required by the specification.

Comments: Facility has COA's on file for all ingredients. Actual points: 20
i20.1 Are all COAs correct, in place and adequate, as required by the specification? N/A: 10 Points
i20.2 Further to i20.1, what was the number of COAs not being correct, not in place or N/A: 10 Points
no adequate?

Q21 Safety Control Points are conducted and documented per the specification.
Comments: Facility conducted safety control point and defined Actual points: 75
HACCP and established CCPs to identified hazard
occurring in their product. They make corrective action,
analyze also documented when deviation occurs in
facility.
This is a critical failure question. If the question score is not 40 points or more, the
audit will be automatically failed. If the score is over 40 points, but there are critical
Alert!
flaws in the processes covered by the question, which may endanger the food safety
control over the RBI Brands products, the audit will also be failed.
i21.1 Are all instances of out of specification situations is processing safety control Yes, instances of
records, properly corrected? out of
specification were
properly
corrected: 15
Points
i21.2 Further to i21.1, were there any instances of out of specification in processing N/A: 25 Points
safety controls, not properly corrected?
i21.3 Are safety control point records well maintained and organized? Yes: 5 Points
i21.4 Are the corrective actions relating to hold, block or retest appropriate and clearly Yes: 10 Points
documented?
i21.5 Are the actions relating to cause of the problem clearly documented? Yes: 10 Points

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i21.6 Is the decision on what to do with out of spec product taken by someone of Yes: 10 Points
sufficient independence and seniority? Is this decision clearly documented?

Q22 Quality Control Points are conducted and documented per the specification.
Comments: Quality control point was conducted as industry Actual points: 30
standard and recorded per the specification.
i22.1 Are all instances of out of specification situations in processing quality control No, out of
records, properly corrected? specification
Quality control points for Chemical Type value BRIX in BK product was 18%. situations were
However refer to spec max brix should be 15%. NOT corrected
i22.2 Further to i22.1, were there any instances of out of specification in processing Only one or two
quality controls, not properly corrected? instances
Quality control points for Chemical Type value BRIX in BK product was 18%. identified were
However refer to spec max brix should be 15%. NOT corrected:
20 Points
i22.3 Are the non-conforming in process products properly identified and segregated? No
Broken product was placed in same chiller with BK finish product and not managed
well. Facility does not separate the chiller for non conforming product. Found some
open containers filled with nonconforming product in chiller area.
i22.4 Is rework processed according to RBI specification? Yes: 10 Points

Q23 Performance Standards and sensory evaluations are conducted using the required equipment
at required frequencies with results documented per the specification.
Comments: Sensory training was conducted every year and Actual points: 50
sensory evaluation conducted for every batch.
i23.1 Is the equipment defined in the specification being used? Yes: 10 Points
i23.2 Is the equipment and product operated and calibrated according to RBI Yes: 10 Points
procedures?
i23.3 Are sensory evaluations done as per the frequency and attributes defined in the Yes: 10 Points
specification?
i23.4 Are the sensory evaluations done by a team of people trained on the products Yes: 10 Points
characteristics?
i23.5 Are sensory evaluations recorded using RBI sensory evaluation procedure and Yes: 10 Points
format?

Q24 QC records are factually completed and all attributes tested per the frequencies stated in the
specification. (Chemical - 30, Physical - 30, Microbiological - 30).
Comments: Facility conducts test for microbiology product by third Actual points: 80
party every year.
This is a critical failure question. If the question score is not 40 points or more, the
audit will be automatically failed. If the score is over 40 points, but there are critical
Alert!
flaws in the processes covered by the question, which may endanger the food safety
control over the RBI Brands products, the audit will also be failed.
i24.1 Are all Chemical finished product control records in compliance with the There are records
specification? not completed to
Quality control point for section chemical finished product criteria Brix was not same as frequency and/or
spec, according to spec maximum brix should be 15%, however range actual for brix results out of
in facility was 15-20%. specification
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i24.2 Further to i24.1, were chemical records not completed to frequency and/or One or two
results out of specification observed? instances of
nonconformance
identified: 20
Points
i24.3 Are all physical finished product control records in compliance with the Yes, all records
specification? are in
compliance: 10
Points
i24.4 Further to i24.3, were physical records not completed to frequency and/or results N/A: 20 Points
out of specification observed?
i24.5 Are all microbiological finished product control records in compliance with the Yes, all records
specification? are in
compliance: 10
Points
i24.6 Further to i24.5, were microbiological records not completed to frequency and/or N/A: 20 Points
results out of specification observed?

Q25 Product falling outside of the specification is documented, with retesting, hold/reject actions
and final disposition clearly indicated.
Comments: All product out of specification was held and Actual points: 75
documented.
This is a critical failure question. If the question score is not 40 points or more, the
audit will be automatically failed. If the score is over 40 points, but there are critical
Alert!
flaws in the processes covered by the question, which may endanger the food safety
control over the RBI Brands products, the audit will also be failed.
i25.1 Are all instances of out of specification situations in finished product control Yes, all situations
records, properly corrected? were properly
corrected: 15
Points
i25.2 Further to i25.1, how many out of specification situations in finished product N/A: 30 Points
records were NOT properly corrected?
i25.3 Are the corrective actions relating to hold, block or retest appropriate and clearly Yes: 10 Points
documented?
i25.4 Are the non-conforming products properly identified and segregated? Yes: 20 Points

Q26 Packaging materials meet specifications.

Comments: Inner and outer packaging material meets the Actual points: 10
specification, there was difference range 0.05 weight for
outer carton.
i26.1 Is the inner packaging for all products inspected according to specification? Yes: 10 Points
i26.2 Is the outer packaging for all products inspected according to specification? No
Specification minimum for outer packaging was 0.38 KG, however actual weigh for
outer packaging for BK was 0,375 KG.

Q27 Primary and secondary packaging are labeled or coded per the specification and are legible.
Comments: Label correct in BK product. Actual points: 20

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i27.1 Is the label correct in all products? Yes: 10 Points

i27.2 Is the label and code legible in all products? Yes: 10 Points

Q28 The ingredient statement matches the specification.

Comments: Facility did not write ingredients statement in packaging Actual points: 50
as not requested in specification.
i28.1 Are all ingredient statements correct, word by word, vs. the RBI specification Yes, all ingredient
(Food Ingredient Questionnaire – FIQ)? statements
correct: 10 Points
i28.2 Further to i28.1, how many instances of incorrect ingredients in statements were N/A: 15 Points
observed?
i28.3 Further to i28.2, more than one instance of incorrect ingredients in statements N/A: 25 Points
were observed?

Q29 The shelf life is correct.

Comments: The shelf life was correct in packaging as per Actual points: 15
specification requested.
i29.1 Is the shelf life correctly printed in the final product? Yes: 5 Points
i29.2 Is the shelf life consistent with the RBI specification? Yes: 5 Points
i29.3 Is shelf life testing done on a regular basis and correctly documented? Yes: 5 Points

Q30 Finished palletized product is in good condition with proper case sealing.
Comments: Found finished product for other customer was stored Actual points: 15
on floor without pallet in chiller room.
i30.1 Is finished product outer container in good condition? Yes: 10 Points
i30.2 Is finished product outer container sealed with proper case sealing? Yes: 5 Points

Q31 Product temperatures are per the specification: raw materials, in process, at packaging, in
storage and at time of shipment.
Comments: Product temperature meets RBI specification. Actual points: 40
i31.1 Are all product temperatures within 0.5°C (1°F) or less of the specification range? Yes, all
temperatures are
within range: 10
Points
i31.2 Further to i31.1, are all temperatures within 1.5°C (3°F) or less of the N/A: 10 Points
specification range?
i31.3 Further to i31.2, how many temperatures more than 1.5°C (3°F) of the N/A: 20 points
specification range?

Q32 Product evaluated at time of the visit meets specifications.

Comments: All product evaluated during audit was meet with Actual points: 80
specification.
i32.1 Are all products evaluated in compliance with the specification? Yes, all products
evaluated are in
compliance: 20
Points
i32.2 Further to i32.1, how many products evaluated were not in compliance with the N/A: 30 Points
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specification?
i32.3 Further to i32.2, three or more products evaluated were not in compliance with N/A: 30 Points
the specification?

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