Application of failure mode and effect analysis and cause and effect analysis and Pareto diagram in conjunction with HACCP to a chocolate-producing industry: A case study of tentative GMO detection at pilot plant scale

Abstract

Although the application of hazard analysis critical control point in the food industry dates back to the 1970s, a more quantitative and reliable approach towards risk assessment became feasible through application of failure mode and effect analysis (FMEA) model. A tentative approach of FMEA application to a filled chocolate-producing industry was attempted in an effort to exclude the presence of genetically modified organisms (GMOs) in the final product. This is of crucial importance both from the moral (ethics) and the legislation (EC 1829/2003; EC 1830/2003; EC 18/2001) point of view. Two structured methods (preliminary hazard analysis and fault tree analysis) were used to analyse and predict the occurring failure modes in food chain system, based on the functions, characteristics and/or interactions of the ingredients or the processes, upon which the system depends. Cause and effect diagram (also known as Ishikawa, tree diagram and fishbone diagram) and Pareto diagram emerged as two very useful and effective tools towards optimising the GMO detection potential of FMEA.