Non-Edible Grocery Manufacture and Product Technical Guide

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Non-Edible Grocery Manufacture and Product
Technical Guide

                   Issued By:                  Authorised By:            Date of Issue    Page No.
                                              Liz Cremer-Evans
                 David Chapman
Version 3                               (Head of Technical Governance   December 2013    Page 1 of 19
            (Non-Food Policy Manager)
                                                 – Non-Food)
Contents Page
1.0     Introduction

2.0     Getting Started
        2.1    ASPECT
        2.2    SVA

3.0     Technical approval and maintenance
        3.1    BRC Certification
        3.2    Walmart audits
        3.3    ASDA technical visits
        3.4    Technical review

4.0     Manufacturing Requirements
        4.1 Management commitment to systems
              4.1.1 Withdrawing and recalling products
              4.1.2 Root cause and incident management
              4.1.3 Customer complaints and handling questions about enforcement
              4.1.4 Packaging and label control
              4.1.5 Traceability
              4.1.6 Concessions
              4.1.7 Control of out-of-specification and surplus product

        4.2 Assessment of Asda requirements

        4.3 Controlling raw materials and processes
               4.3.1 Chemicals
               4.3.2 Genetically Modified Products
               4.3.3 Irradiation

        4.4 HACCP
               4.4.1   Factory operational standards
               4.4.2   Raw material and packaging supplier management
               4.4.3   Training
               4.4.4   Managing allergens
               4.4.5   Detecting and controlling foreign bodies
               4.4.6   Managing pest control
               4.4.7   Managing pesticides
               4.4.8   Controlling water quality

        4.5 Development
               4.5.1 7 Gate Process
               4.5.2 New Product Development

5.0     Supplier Charges

                       Issued By:                  Authorised By:            Date of Issue    Page No.
                                                  Liz Cremer-Evans
                     David Chapman
Version 3                                   (Head of Technical Governance   December 2013    Page 2 of 19
                (Non-Food Policy Manager)
                                                     – Non-Food)
6.0     Contact Details

                       Issued By:                  Authorised By:            Date of Issue    Page No.
                                                  Liz Cremer-Evans
                     David Chapman
Version 3                                   (Head of Technical Governance   December 2013    Page 3 of 19
                (Non-Food Policy Manager)
                                                     – Non-Food)
1.0 Introduction
        This guide covers all ASDA Brand own label, including direct imports or any other
        exclusive to ASDA, Non-Edible Grocery (NEG) products. It does not apply to NEG
        products which are considered to be a food or where the 3rd party accreditation is a
        Food Standard (e.g. BRC Food Safety Standard).

        This guide:
        Must be read in conjunction with relevant ASDA supplier Terms and Conditions.
        Must be read in conjunction with relevant ASDA Policies
        Must be read in conjunction with the product specification agreed between ASDA and
        the supplier.

        This Guide is in addition to any legal obligations in relation to the products supplied.
        This document is not exhaustive, and expert advice must be sought where appropriate.

        Where a particular issue is not covered within this guide, the supplier must default to
        legal compliance or recognised industry best practice.

        It is the supplier’s responsibility to communicate the ASDA technical guide and policies
        through their supply chain to ensure compliance.

                        Issued By:                  Authorised By:            Date of Issue    Page No.
                                                   Liz Cremer-Evans
                      David Chapman
Version 3                                    (Head of Technical Governance   December 2013    Page 4 of 19
                 (Non-Food Policy Manager)
                                                      – Non-Food)
2.0     Getting Started
2.1     ASPECT

We use a system on the web for managing our products called ASPECT. It supports our new
process for developing products, due diligence, protecting our brand and managing our digital
assets.

As this is also our communication tool, you must make sure that:

•       you register to use ASPECT when we invite you;
•       you have picked a nominated person and deputy who have been fully trained on
        ASPECT;
•       all contact details, including an out-of-hours emergency contact name and number, are
        correct at all times; and
•       you log on to the site at least twice a day to make sure that we have not added any
        notifications, and if we have, you pass these on as necessary.

2.2     SVA

        You have a responsibility to make sure that the products, including packaging where
        relevant, you supply to us consistently meet certain analytical, microbiological and
        safety criteria. SVA is our chosen testing laboratory where all first production and
        routine surveillance testing is carried out on our brand products.

        You must register with SVA before you supply any product to us.

        You must have a nominated person and deputy who has been trained on the E-learning
        modules on the SVA Portal.

                        Issued By:                  Authorised By:            Date of Issue    Page No.
                                                   Liz Cremer-Evans
                      David Chapman
Version 3                                    (Head of Technical Governance   December 2013    Page 5 of 19
                 (Non-Food Policy Manager)
                                                      – Non-Food)
3.0       Technical approval and maintenance

You must not compromise product safety, legality or ASDA brand integrity. You must, at all
times, operate within the realms of ASDA requirements and any third party certification.

      •   We can visit manufacturing and packing sites to check you have effective controls in
          place to assure the safety, legality and quality of ASDA-brand products. These visits may
          be announced or unannounced, depending on the circumstances.
      •   Relevant people at the appropriate level of seniority must be available to escort ASDA
          colleagues around the site, allowing unhindered access to the operation and associated
          documentation, whilst ensuring their safety.
      •   You must make all records relating to Asda products available if we ask during visits or
          as part of any investigation.
      •   You must keep these records for at least ten years or longer if required by law.

   3.1 BRC certification

          Before you start to supply products to us, you (the manufacturing and or packing site)
          will have to be successfully audited and certificated against the current issue of the BRC
          Consumer Products Standard.

   3.2 Walmart Audits

          When you start to supply us, you will need to have an ethical audit. This audit is
          conducted by an independent organisation and you must pass this audit.
          For certain categories of products, you may also need a Walmart security audit.

          If you are a direct import supplier, you will need to have a Factory Capability and
          Capacity Audit (FCCA). This audit is conducted by an independent organisation and you
          must pass this audit. You must disclose all manufacturing sites on Retail Link and follow
          the FCCA audit programme.

      3.3 ASDA Technical Visits

          Our technical team will assess what visits we need to carry out. Usually the visits will be
          as follows.

          Supplier approval visit -This is a first-stage visit to new suppliers or manufacturing sites
          where we will assess your suitability and capacity to supply ASDA-brand products in line
          with our policies and manufacturing standards. Whilst there may be no evidence of you
          keeping to our policies, we will assess your current position in doing so.
          1st production run visit - We will assess the launch of a new product against the agreed
          specification and appropriate policies.

                          Issued By:                  Authorised By:            Date of Issue    Page No.
                                                     Liz Cremer-Evans
                        David Chapman
Version 3                                      (Head of Technical Governance   December 2013    Page 6 of 19
                   (Non-Food Policy Manager)
                                                        – Non-Food)
Reactive incident management visit - This is in response to any product safety or legal
        challenge where we will carry out investigations to find the root cause and deal with the
        issue.
        Asda Audit (AA) - This is a full and comprehensive audit to assess how you are
        performing in keeping to our agreed standards and policies. This will include a full
        traceability exercise on an ASDA product we choose at random. This audit will be
        unannounced and carried out by our nominated 3rd party, SAI Global.

        Scoring System:
        At the end of a technical visit we will score the site as follows:

        Pass            Visit objectives and expectations met
        Fail            There is an imminent product safety and/or legal risk

        We will agree a timescale with you on dealing with any points raised and issue a report.

   3.4 Technical Review

        If you compromise product safety, legality or brand integrity, we will carry out a risk
        assessment to decide if we need to place you on technical review.

        Technical review is there to make sure that you take steps to correct the root cause of
        the identified issues. We need to the right thing by our customers. The review will last
        no more than six months. The aim is to make sure that any problems are put right.

        Technical review may apply to a single site, many sites or a supplier's entire business
        with us.

        While on technical review you will need to suspend all new product development (NPD)
        activities and we will review products currently being developed or those being
        redeveloped.

        Initial notice
        This will be face-to-face or over the phone, followed by email confirmation from the
        Category Director to your Senior Technical Manager (STM) and Managing Director (MD).
        This confirmation will summarise the scope and reasons for starting the technical
        review. This will happen as soon as the issue has been identified.

        Initial meeting
        Within seven days of our notice, your MD and STM must present a “Correction of
        Errors” (COE) Plan to our representatives at a location we chose. You will send this plan
        to our technical manager at least 2 working days before the initial meeting.

        We will agree the technical review timeframe will you at this meeting. If timeframes
        unavoidably extend the review period beyond 6 months, you must be able to prove that
        you have temporary solutions in place to get rid of any possible concerns linked to
        product safety, legality and brand integrity.

                        Issued By:                  Authorised By:            Date of Issue    Page No.
                                                   Liz Cremer-Evans
                      David Chapman
Version 3                                    (Head of Technical Governance   December 2013    Page 7 of 19
                 (Non-Food Policy Manager)
                                                      – Non-Food)
Ongoing review
         This will include site visits and meetings where appropriate.

         Removing the technical review – Re-issuing Technical Approval
         At the end of the review period, we will carry out a site visit and final review meeting to
         decide whether we can remove the ‘technical review’ status. If you fail to achieve this
         within the agreed timeframe, we will remove the technical approval you need to be able
         to supply us.

         If you then need to return to ‘technical review’ within a two-year period after closing
         the previous technical review, we will suspend technical approval and will decide, based
         on risk assessment, whether to reinstate your supply.

4.0      Manufacturing Requirements

      4.1 Management commitment to systems

         To prove that your senior management are committed and have the right support to
         putting product-safety and quality-management systems for all our own-brand products
         into practice, you must have the following in place.

   •     You will need to have enough personnel to meet our requirements on an ongoing basis
         and to meet your operational and technical commitments. You will need to ensure
         sufficient factory capacity is maintained for supply of ASDA Brand products.
   •     All requests for information must be given to the relevant ASDA representative within
         the timescale we have asked for.

         4.1.1 Withdrawing and recalling product

         A product withdrawal relates to removing a product that is at depot or store, whereas a
         product recall is aimed at returning the product from the depot or store and also from
         consumers who have already bought it.

   •     You must tell us as soon as you are aware of the incident and record details of all stages
         of any incident. You can contact us direct using the following details:

         During office hours, contact the relevant ASDA category technical or product manager.

         Outside office hours, and in an emergency only, phone 0044 (0)1416-472000.

   •     If you need to call us about an incident, you must be able to give us the following
         information.
   •     Your name, address and phone number
   •     A brief description of the problem
   •     The brand name and full name of the product involved

                         Issued By:                  Authorised By:            Date of Issue    Page No.
                                                    Liz Cremer-Evans
                       David Chapman
Version 3                                     (Head of Technical Governance   December 2013    Page 8 of 19
                  (Non-Food Policy Manager)
                                                       – Non-Food)
•       A product description
   •       The pack size, variation and type of packaging (in other words, a single, multipack and so
           on)
   •       Details of the best-before/expiration date or production date
   •       Stores or regional distribution centres the product was sent to
   •       Details of government or local authority involvement, for example, the police, HSE,
           Environmental Health, Trading Standards and so on.
   •       Other supplier or product information (if available), for example, your ASDA supplier
           vendor number; POM (number) for product; SIN (number) for product; GRN (number)
           for supplier; Walmart ID number; barcode; ASDA-brand specification number.
   •       You must have a documented management system in place to show how any potential
           or actual breaches of product safety, legality or quality requirements for ASDA-brand
           products will be handled. For example, what you would do if there was alleged allergic
           reaction, serious complaints about the presence of a foreign body, out-of-specification
           product and so on.
   •       You must test your withdrawal and recall procedure on Asda product once a year.

           4 .1.2 Root cause and incident management

    • You must be able to show that you investigate incidents back to their root cause and
      take action to make sure you fully deal with incidents and prevent them from happening
      again. All incidents affecting ASDA-brand products must be documented and reported to
      your ASDA technical contact.

    • If capital is needed, you must put a suitable interim system in place to manage risk.

           4.1.3 Customer complaints and handling questions about enforcement

           A thorough and effective system for handling complaints is an essential part of your
           product safety and quality systems. It gives an essential measure of product quality and
           identifies opportunities for ongoing improvement. We will log all complaints we
           received on our complaints system, CPQC. This is coordinated by the ASDA Customer
           Contact Centre. Our technical governance team will email you each week if there are
           any complaints about products you have supplied.

       •     You must give us an email address which we will use to send the weekly complaints
             report to.
       •     You must have a system in place to effectively gather, handle and manage complaints
             we may raise. You should fully document records of investigations and analyse any
             trends which should include the product, production line, production shift,
             production date, best-before date and so on.
       •     You must carry out corrective action which is appropriate to the seriousness and
             frequency of the problems identified. This should be done by appropriately trained
             personnel.

                          Issued By:                  Authorised By:            Date of Issue    Page No.
                                                     Liz Cremer-Evans
                        David Chapman
Version 3                                      (Head of Technical Governance   December 2013    Page 9 of 19
                   (Non-Food Policy Manager)
                                                        – Non-Food)
•       Unless there are exceptional circumstances and a justifiable reason you must not
               contact customers, the media, enforcement bodies (for example, Environmental
               Health, Trading Standards) , government organisations (for example, DEFRA) and
               consumer associations (for example, Which?) direct on matters relating to the safety,
               legality and quality of ASDA-brand products. These should be referred to us
               immediately.
       •       You must be able to prove that you use the outcomes of any complaint investigations
               to continually improve safety and quality standards.
       •       You must, as a minimum, deliver a year-end rolling average of complaints at or below
               the target level we set for you.

           4.1.4 Packaging and label control

           It is essential that you have effective working procedures and control checks in place to
           make sure that you always apply the specified packaging, labels and product-coding
           information to ASDA-brand products. Procedures must be in place for:

           •       Printed packaging and label intake and storage; and
           •       Issuing packaging, including components, to and from production
           •       You will implement fail-safe systems and control methods

           4.1.5 Traceability

           You must be able to trace all raw materials, including packaging, back to source and
           follow these through all stages of production, processing & distribution to an ASDA
           depot or ASDA nominated distribution facility.

    • You must carry out a documented traceability exercise, on an ASDA-brand product at
       least every 12 months unless we agree differently with you.
    • The Asda-brand products you choose for the traceability exercise must be chosen based
       on the risk associated with the raw materials (e.g. country of origin, complexity of
       recipe, complexity of formulation, complexity of supply chain and so on).
   • The exercise must include a full quantity and mass balance, from a single day’s
      production, with full traceability being completed within 4 hours.

           4.1.6 Concessions

           It is your responsibility to make sure that the product specification accurately reflects
           the supplied product and meets all our policies. Under exceptional circumstances, we
           may grant you a temporary concession.

           All concessions must be agreed in writing prior to any changes with the relevant ASDA
           Category Technical Manager and/or Product Manager.

           4.1.7 Controlling out-of-specification and surplus product

                            Issued By:                  Authorised By:            Date of Issue     Page No.
                                                       Liz Cremer-Evans
                          David Chapman
Version 3                                        (Head of Technical Governance   December 2013    Page 10 of 19
                     (Non-Food Policy Manager)
                                                          – Non-Food)
To help you get rid of out-of specification or surplus product that is safe to use, we have
        entered into an agreement with ‘Company Shop Limited’ to allow them to buy ASDA-
        brand products in its packaging from you with the packaging still in place. This
        agreement does not apply to products in our pharmacy (over the counter and grocery
        lines) and optical range or our Little Angel brand. They will sell these products through
        approved outlets under their control. As part of the agreement, 'Company Shop' will ink
        jet a code on the label to indicate the product is only for sale through those outlets.

        Where out-of-specification or surplus ASDA-brand product is sold/ given away as staff
        sales or to a third party, the following must be adhered to:

        • All stock must be traceable.
        • Any product that is unsafe to use must not make its way into the supply chain. For
          example, it must be crushed, dyed, and so on or you can use our approved operators
          to get rid of the ASDA-brand product in its packaging.
        • To make sure that our brand integrity is not compromised, you must not sell products
          to any jobber or any other outlet other than ‘Company Shop’ without our written
          permission.
        • When selling to outlets other than ‘Company Shop’ you must completely remove the
          ASDA brand name at the site of manufacture, on both the outer and primary
          packaging, including both front and back labels.

                        Issued By:                  Authorised By:            Date of Issue     Page No.
                                                   Liz Cremer-Evans
                      David Chapman
Version 3                                    (Head of Technical Governance   December 2013    Page 11 of 19
                 (Non-Food Policy Manager)
                                                      – Non-Food)
4.2 Assessment of Asda Requirements

           You must have audits in place to challenge the hygiene, product safety, quality and legal
           standards.

           • Audits of ASDA’s policies must be carried out a minimum of annually.

   4.3 Controlling raw materials and processes

           4.3.1 Chemicals

           All our non-food products must comply with the requirements of the ASDA Chemicals
           Policy and inclusion of chemicals above the specified limit is not permitted. This policy
           applies to all parts of the product, including all internal components and packaging.

           In addition to the above we require all of the plastic items in our Little Angels baby
           range to be BPA-free.

           You must make sure that any COSHH safety data sheets are sent to the relevant Asda
           Product Manager. There must be a process in place to ensure that the safety sheet is
           validated as being current.

           Materials that have been identified as high risk through risk assessment must have
           appropriate controls in place.

           4.3.2 Genetically Modified Products

           We do not allow you to use genetically modified ingredients or ingredients produced
           from genetically modified organisms.

       •     You must hold written guarantees that all ingredients (including the parts of any
             compound ingredients) used in manufacture have not been genetically modified or
             produced from genetically modified organisms.
       •     Non-GM components can sometimes be of GM origin or derived from GMOs. These
             are supplied from ‘identity preserved’ (IP) sources.
       •     You should carry out product testing based on a risk assessment of the materials and
             their source history. You must keep the results of this testing for us to inspect as well
             as any certificates of conformance (COC) received.
      •      Materials that have been identified as high risk through risk assessment must have
             appropriate controls in place.

           4.3.3 Irradiation

           We do not allow you to use irradiated ingredients.

                           Issued By:                  Authorised By:            Date of Issue     Page No.
                                                      Liz Cremer-Evans
                         David Chapman
Version 3                                       (Head of Technical Governance   December 2013    Page 12 of 19
                    (Non-Food Policy Manager)
                                                         – Non-Food)
•     You must hold written guarantees that all ingredients (including the parts of any
             compound ingredients) used in manufacturing the product have never been
             irradiated.
       •     You should carry out product testing based on a risk assessment of the materials and
             their source history. You must keep the results of this testing for us to inspect as well
             as any certificates of conformance (COC) received.
       •     Materials that have been identified as high risk through risk assessment must have
             appropriate controls in place.

       4.4 HACCP

           To supply us you must have an HACCP (Hazard Analysis Critical Control Point) system
           which is focused on identifying the critical points in a process where safety hazards
           could arise. You then need to put control steps in place to prevent them.

           Documented risk assessments and studies must be produced for all products and
           released to ASDA by attaching them to the product specification on ASPECT. ASDA
           expects its suppliers to be able to demonstrate that the principles of this approach is a
           way of working within their business, and that it is equally understood and respected by
           all members of the manufacturing and management teams

           Suppliers must be able to demonstrate that appropriate principles and studies have
           been carried out by a multidisciplinary team and that the team leader has been
           adequately trained.

           Principles of HACCP studies should be based on the following process:-
   •       Process flow diagrams drawn for each process.
   •       Potential hazards, associated with each process step, identified and documented.
   •       A decision tree used to define the Critical Control Points (C.C.P.).
   •       The control target levels and tolerances must be defined in order to ensure that each
           C.C.P. is controlled.
   •       This must be verified by a suitable monitoring system with documented work
           instructions. Critical Control Points must be controlled and monitored at all times.
   •       Corrective action must be documented in order to define the action required when the
           C.C.P. is moving out of control.
   •       Verification procedures must be implemented to confirm the effectiveness of the
           system, with corrective action taken as appropriate.

           4.4.1 Factory operational standards
   •       You must make sure that the site operates and keeps to good manufacturing standards
           in all areas at all times.
   •       The factory, facilities and equipment must be adequately maintained and kept in a clean
           and tidy condition to make sure there is no risk to ASDA-brand products.
   •       The factory must be maintained to a standard which prevents pests from entering it.
                          Issued By:                  Authorised By:            Date of Issue     Page No.
                                                     Liz Cremer-Evans
                        David Chapman
Version 3                                      (Head of Technical Governance   December 2013    Page 13 of 19
                   (Non-Food Policy Manager)
                                                        – Non-Food)
•       Your process controls must be good enough to make sure you keep to specification and
           legal compliance.
   •       You must have controls in place to reduce, as far as possible, the risk of cross-
           contamination.

           4.4.2 Raw material and packaging supplier management
   •       The site must have an effective system in place to control raw materials and suppliers
           for all raw materials used in ASDA-brand products.
   •       You must carry out a risk assessment for all raw materials and packaging.
   •       The minimum controls in place for approving and monitoring suppliers must include:
           • a supplier audit questionnaire which should have been signed off by the site
           technical department; and
           •  an approved raw-material list which includes all raw materials that go into ASDA-
           brand products.

           4.4.3 Training
           All factory employees must be suitably trained for the tasks they carry out.

           4.4.4 Managing allergens

           Certain ingredients can cause serious allergies in some people, which can pose a danger
           to health, potentially fatal, if absorbed or inhaled.

   •       You must have an active management system which reduces, as far as possible, the risk
           of allergen contamination of products and make sure you keep to legal labelling
           requirements.

   •       Suppliers must carry out a site risk assessment to establish which ingredients pose a risk
           and put controls in place to reduce product contamination as far as is possible. The risk
           assessment plan must be available for us to inspect.

           4.4.5 Detecting and controlling foreign bodies

               You must have effective programmes in place to prevent foreign bodies from entering
               product.

       •        All areas of the factory must be maintained and be in a condition which will prevent
                the risk of product contamination.
       •        You must tell us if there is building or other work taking place that will affect ASDA
                production or where the safety of ASDA-brand products may be compromised.
       •        You will need to carry out a risk assessment to identify any risks of foreign bodies
                entering product and put controls in place to reduce product contamination as far as
                possible.
       •        You must use effective detection systems which meet industry best practice in design
                and technology. If it applies they should be able to detect and reject foreign bodies in
                             Issued By:                  Authorised By:            Date of Issue     Page No.
                                                        Liz Cremer-Evans
                           David Chapman
Version 3                                         (Head of Technical Governance   December 2013    Page 14 of 19
                      (Non-Food Policy Manager)
                                                           – Non-Food)
different packaging formats. These systems can include metal detectors, x-rays,
              sieves and magnets.
        •     Contaminated product must be automatically rejected from the production line and
              isolated from unaffected product. Only authorised personnel should be able to
              handle the contaminated product.
        •     You must put in place a fail-safe system and control methods.
        •     You must have a detailed procedure that includes the frequency of testing, how you
              will handle rejected material and actions to take if a system fails.

            4.4.6 Managing pest control

            You must have an effective programme in place for managing pests, which must cover
            all areas of the site to reduce, as far as is possible, infestation by pests. Pest control
            includes the whole manufacturing site and all areas that are involved in making
            products.

            If you employ an external contractor, they must be a member of the British Pest Control
            Association (BPCA) or an equivalent accredited local or national organisation. Methods
            to control pests should take into consideration any “cultural” methods of capturing
            pests.

   •        You must report any pest infestation immediately to your ASDA technical contact if
            there is a risk to Asda brand products.
   •        You must tell your Asda technical contact in writing about any ongoing pest activity that
            has not been dealt with within six weeks if there is a risk to product safety. This must be
            within 5 working days after the 6 week period. You will need a plan in place showing the
            action to be taken and the timescales.

            4.4.7 Controlling water quality

            Water used as an ingredient or in direct contact with products, or water which is used as
            an ingredient for washing or cooling product, must be risk assessed to make sure that at
            all times it can be maintained free from pathogens, including protozoans, or
            contamination which may affect product quality.

    •        You must make sure that you use suitable treatment and processes.
    •        Checks and controls must be in place to make sure the treatments and processes stay
             effective.
    •        We must be told immediately in writing if there are any problems with water quality
             which may affect product safety or quality.
    •        You must also have contingency plans in place for a serious interruption to the supply
             or contamination. You must also check on the availability of other supplies.

                            Issued By:                  Authorised By:            Date of Issue     Page No.
                                                       Liz Cremer-Evans
                          David Chapman
Version 3                                        (Head of Technical Governance   December 2013    Page 15 of 19
                     (Non-Food Policy Manager)
                                                          – Non-Food)
4.5 Development

            4.5.4 7 Gate Process

            ASDA brand’s ‘7 Gate’ process gives details of the tasks, responsibilities and critical
            timelines to make sure that new (including amended) products are launched in line with
            commercial, marketing and customer demands and are always safe, legal and meet
            certain quality standards. It represents a (maximum) 40-week process from the point
            where the idea for a product is developed to when it is launched. Each ‘gate’ in the
            process represents an important hurdle for which you must have completed identified
            tasks in the process before moving to the next ‘gate’. You can get training details on this
            from your ASDA Project Manager

       •    You must understand your role and responsibilities within the overall 7-gate process
            and make sure you keep to the stated timelines linked to the tasks you are responsible
            for.

            4.5.5 New Product Development

            You must have a system in place for developing new products and keep records to prove
            that all ASDA-brand products have been developed in line with the procedure.
.
       •    You need a documented system for product design and development system that
            includes a hazard analysis study when developing new product and reformulating
            products to make sure that the products are adequately assessed for safety, quality and
            legality.
       •    You must carry out factory trials on factory-commissioned equipment. You should
            collect the information for claim substantiation, performance data and include microbial
            testing, and ingredient breakdown such as preservation studies or stability testing.
       •    You will need to carry out a risk assessment of any new raw materials and product to
            check that they are being handled and stored correctly and the influence they have on
            other products. This must include transit trials for new packaging.
       •    You will need to carry out shelf-life trials on factory-trial products and keep documents
            on them. All products must be safe, physically and visually acceptable throughout the
            shelf-life of the product. This includes during storage by manufacturers, the distribution
            chain, and storage at store and by the customer.
       •    Any product requiring 3rd party testing (e.g. ISO standard testing) must be completed
            using an UKAS accredited laboratory. These results must be sent to your relevant Asda
            Product Manager and Technical Manager for their review. Test reports are valid for one
            year from the date of testing and must be re-tested so the reports run back to back.
       •    All relevant parts of the product specification must be sufficiently validated and / or
            verified. This includes country of origin, shelf life/stability, recipe/formulation, customer
            storage instructions, customer instructions for use, label/ ingredient declaration
            (including quids), raw material sourcing, allergen declaration and claims, warnings and
            mandatory statements.
       •    Agreed Specifications must be in place for all launched products and must be accurate.

                            Issued By:                  Authorised By:            Date of Issue     Page No.
                                                       Liz Cremer-Evans
                          David Chapman
    Version 3                                    (Head of Technical Governance   December 2013    Page 16 of 19
                     (Non-Food Policy Manager)
                                                          – Non-Food)
Issued By:                  Authorised By:            Date of Issue     Page No.
                                              Liz Cremer-Evans
                 David Chapman
Version 3                               (Head of Technical Governance   December 2013    Page 17 of 19
            (Non-Food Policy Manager)
                                                 – Non-Food)
5.0 Supplier Charges

We can charge suppliers for certain activities. These include but not exclusively:

   •    Reactive supplier visits;
   •    Retrospective charge-back if you fail an audit;
   •    Customer complaints and our associated investigation costs;
   •    Product recalls and withdrawals;
   •    Samples for third-party consumer testing (including failure to deliver, late cancellation,
        non-delivery of product; delivery beyond agreed time and so on);
   •    First production samples and analysis;
   •    Routine surveillance product testing and examination (including any tests in response to
        reports of out-of-specification results or incidents); and
   •    Testing claims on packaging.

                       Issued By:                  Authorised By:            Date of Issue     Page No.
                                                  Liz Cremer-Evans
                     David Chapman
Version 3                                   (Head of Technical Governance   December 2013    Page 18 of 19
                (Non-Food Policy Manager)
                                                     – Non-Food)
6.0     Contact Details
ASPECT
Helpdesk: +44(0) 1274 202 356

SVA
Jonathon Elliot (Tel: 01530-56100); e-mail: portaladmin@svaltd.com

Company Shop
Contact: Lee Wood (Trading Director), Company Shop Limited, New Road, Tankersley, Barnsley,
South Yorkshire S75 3BQ. Tel: 01226-748324; E-mail: lee.wood@companyshop.ltd.uk

                      Issued By:                  Authorised By:            Date of Issue     Page No.
                                                 Liz Cremer-Evans
                    David Chapman
Version 3                                  (Head of Technical Governance   December 2013    Page 19 of 19
               (Non-Food Policy Manager)
                                                    – Non-Food)
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