CN103019121A - Computer-based intelligent control method for food safety and quality - Google Patents
Computer-based intelligent control method for food safety and quality Download PDFInfo
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- CN103019121A CN103019121A CN2012105449662A CN201210544966A CN103019121A CN 103019121 A CN103019121 A CN 103019121A CN 2012105449662 A CN2012105449662 A CN 2012105449662A CN 201210544966 A CN201210544966 A CN 201210544966A CN 103019121 A CN103019121 A CN 103019121A
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Abstract
The invention relates to a computer-based intelligent control method for food safety and quality. Hazard analysis and establishment of a critical control point system, real-time monitoring of food production data, a remote monitoring system for food production, a food safety quality manual and establishment of resource management are included. An intelligent and automatic management system for control of food safety and quality is achieved by using the computer intelligent management technology. Widely and internationally accepted food standards are consulted and integrated and serve as guidance, the computer is combined, automatic planning for the food production process is performed firstly, then automatic control for critical control points in production is performed, and management association analysis for the whole production process is performed from an overall perspective; and standard and shared databases are updated in real time through the cloud technology to guide production rules, and food production safety is guaranteed through the latest technologies.
Description
Technical field
The present invention relates to food security, quality intelligent control method, belong to intellectuality planning and the process control technology field of food industry.
Background technology
Existing food control automatic mode mainly is to help to carry out document control, product inventory management, shelf-life registration, sales figure, but can not intelligent carry out the most basic HACCP(hazard) decision-making, therefore can not be from the source, fundamentally control safety and the quality of food.Basically just be used in the ERP software system of food industry.Much be as carrier take online software, but it can not be well combines with the hardware of manufacturer end, traditional desktop software then, can not upgrade compromise data storehouse and process operation database, cause performed process can not embody up-to-date level, even use expired production, control mode.
Summary of the invention
The objective of the invention is to overcome the deficiency that prior art exists, a kind of computer based food security, quality intelligent control method are provided.
Purpose of the present invention is achieved through the following technical solutions:
Computer based food security, quality intelligent control method may further comprise the steps:
1) hazard HACCP Establishing:
1.1 determining of the PRP of HACCP, namely set up the PRP database, based on " food production Hygienic license examination general rule " and with and the detailed rules and regulations of 28 based foods that comprise, the CAC of Codex Committee on Food of the United Nations, GMP GMP and hygienic standard working specification SSOP, comprise that supplier controls, the plant facilities plant maintenance, the workshop is arranged, storage, public utilities, production environment cleaning and health, insect control, staffs training, employee's health, logistics, the safety of factory building, offal treatment, store data-base content into Cloud Server, and carry out management and the analysis of data classification, each information is carried out the ID management, fixing numbering is arranged, when the change database, the data change record management of computing machine is arranged, scheme is divided into basic premise scheme and OPRP two classes;
Supplier is controlled to be an important content in the PRP, comprise supplier audit, approval and supervision, raw material and packing are checked and accepted and are monitored, supplier's control is based on supplier's venture analysis is drawn, the process of risk assessment is quantized, utilize computing machine to determine degree of risk according to result of calculation and the result is carried out the supplier's of computing machine attribute management;
A. at first be raw material venture analysis flow process, according to the raw database screening, draw Risk list, then each raw material is according to the possibility that occurs and two indexs of seriousness of harm, and each index is divided into 1,2,3 three level, and 1 is minimum, 3 for the highest, the seriousness level of the possibility level of raw material risk=generation * harm is if the result who draws=9 or 6 then are excessive risk, if result=4 or 3, then be the moderate risk, if result=1 or 2 then are low-risk;
B. the program of supplier audit, approval and supervision, the considering of risk size that depends on degree of risk that supplier supplies raw materials and supplier itself, after the raw material risk assessment is finished, carry out the risk assessment of supplier own, supplier's estimation flow, score is higher, and risk is larger, assessment has 6 indexs, and each index has corresponding level:
A, whether Third Party Authentication is arranged, have whether to be two levels, be=1, no=3;
B, factory building, device hardware facility have good, qualified, defective three levels, good=1, qualified=2, defective=3;
C, technician's strength, minute good, qualified, defective three levels, good=1, qualified=2, defective=3;
D, product risks degree, minute basic, normal, high three levels, low=1, in=2, high=3;
Whether e, scene have anaphylactogen, minute are, no two levels, be=3, no=1;
F, supplier be the immediate producer of raw material whether, minute is, no two levels;
Risk score=(b+c+ d+e) * a, must being divided into of ideal situation: 4 minutes, if other conditions of supplier are all good, just not authentication then must be divided into 12 minutes, as the border of low-risk and risk; If the each side condition is all qualified, there is not Third Party Authentication, namely b, c, d are each 2 minutes, do not have sensitizer, and mark is 21 minutes, is risk and high risk border; Therefore: mark: 4～12 is low-risk, and 12～21 is the moderate risk, and 21～36 is excessive risk, no matter in any case, if index f is no, then supplier is excessive risk simultaneously;
At last, according to the risk index that draws, determine the control measure to supplier: all have Third Party Authentication all will submit certificate of certification and the audit report of electronic edition;
Raw material and packing are checked and accepted and are monitored, the degree of risk that draws according to raw material is carried out the extraction result of high in the clouds database, operation indicating, when the excessive risk raw material was checked and accepted, every batch all must have examining report, and range estimation when checking and accepting, moderate risk raw material is estimated during examination, and random sampling detects, low risk raw material is estimated during examination;
1.2 the pre-step of hazard analysis: set up raw database, and raw material classifies according to character, character is determining the potential hazard that raw material may carry; After the user inputted raw material, computing machine just read and exports corresponding potential hazard and points out;
Technological process of production database: set up the technological process database, be referenced as country to 28 based food production permit detailed rules and regulations, part as production permit, database comprises 28 series products and corresponding technological process thereof, when the user according to system suggestion inputs the finished product type, just from database, read corresponding data, and the generating process process flow diagram;
Process operation database: this database is with reference to 28 based food production permit detailed rules and regulations and international food code council's standard and food technology technical manual etc., formulate relevant production procedure for different production products, and can make amendment to flow process according to client's demand; Each process operation comprises corresponding manufacturing parameter, the potential hazard that may introduce, eliminable potential hazard, control measure and corresponding corrective action and Key Limit Value; The corresponding production procedure database of each operation in this database;
With being based upon the content of the computer logic relation in the database, by client's selection itself and the content of actual conditions, carry out the inner computer search and screen, and result's content feed to the user;
1.3 hazard analysis: behind the raw material and finished product that computing machine provides according to the user, drawing technological process recommends, then according to raw material and technological process, automatically generate potential hazard tabulation and control measure, the principle that control measure generate automatically is that computer system reads from process operation database and endangers corresponding control measure, then according to flow process, filter out the optimum control measure that meets, computing machine also is to judge according to flow process and the logical relation determined in advance; Then, corresponding to each harm, two indexs are arranged, the possibility and the seriousness that namely occur, each index has three levels, and three levels of possibility are for probably=3, possible=2, impossible=1; Three levels of seriousness are: harmful=3, dislike=2, level=possibility level * seriousness level is then endangered, if income value in unimportant=1〉6, then be conspicuousness harm;
After all harm executed analysis, computing machine filtered out conspicuousness harm, and generated significantly harm tabulation;
1.4 the operability prerequisite is determined: control measure are classified, can not the quantification measure be OPRP, then but quantified controlling is further screened, filter out the control measure that are not included in the PRP database, draw non-PRP control measure tabulation, carry out next step process, namely critical control point is determined, control measure in addition are then as OPRP but not the PRP control measure are tabulated, and computing machine generating run PRP is tabulated;
1.5 determine critical control point CCP, the non-PRP control measure tabulation that filters out more than the computing machine basis is judged each raw material and process operation;
Should judge that for raw material to determine these raw materials of control of whether keeping under strict control during the course, deterministic process is for answering 3 problems that answer is "Yes" and "No"; Problem 1: whether this raw material has relevant harm, will if "Yes" then enters problem 2: you or client remove this harm if "No" then continue to analyze other raw material? if "No" then is sensitive raw material, highly control; If "Yes" then enters problem 3: out of contior cross-infection is arranged? if "No" then continues to analyze other raw materials, if "Yes" then is sensitive raw material, highly control;
Then, per pass process operation is judged that determination methods is comprised of 5 problems, to each question answering "Yes" and "No", process is as follows: problem 1: is there harm in this step? if "No" then is not CCP; Can if "Yes" then enters lower problem 2: this harm be controlled? is if the answer "No" is then answered a question: controlling in this step to guarantee that safety is necessary? if "No" then is not CCP, if "Yes", then modification and processing operation or product; If problem 2 is answered "Yes", is is then enter problem 3: this operation used for especially eliminating harm or harm reduced to acceptable level? if "Yes" is CCP, if "No" enters problem 4: might occur to pollute or endanger to be increased to and to accept level? if "No" then be not CCP, is does if "Yes" then enter problem 5: the trade union that adds afterwards eliminate risk or it reduced to acceptable level? if "Yes" then be not CCP, if "No" then be CCP; After above logic judgement, computing machine filters out CCP, generates the CCP tabulation, then screens supervisory programme and Key Limit Value that output meets, and corrective action, and generation tabulation in process steps; According to the definite CPP control case in the database in the production procedure that automatically generates, carry out basic CPP reference mark in addition;
1.6 HACCP confirms that computing machine is invoked at the HACCP plan that produces in the step 1.5, calculates the plan that generates before looking back;
Whether 1.7 HACCP verifies planning: make a plan, checking HACCP plans in actual production, effectively carry out, and the planning of checking comprises audit production run record, internal check, finished product test, Customer Complaint record and trend analysis;
1.8 trackability system made: set up finished product batch scheme, the lot number that 3 kinds of forms are arranged, practical condition according to the client, the date of the minimum degree of accuracy that allows for producing, namely, according to batch number of producing in a day of family input, if system recommendation batch number form is a collection of, then batch number is date or its corresponding number, if produced more than a collection of in one day, then the batch number form of system recommendation is added a numeral, represents certain batch in a day, if each batch has many machines to finish, then batch form of system's generation is added one digit number again, and every machine has corresponding numeral, separates with separator bar in the middle of the numeral; Set up raw material batch number, the bar code that the raw material of every batch every kind warehouse-in is all produced by computer system, give specific lot number, when putting into production, scanning bar code, record the used raw material batch of certain batch products, if when producing semi-manufacture with raw material, use and same mode, come mark with bar code, when putting into production, by scanning to record batch, finished product batch can with the raw material that uses or half-finished batch and relevant critical control point monitor record on same form, be recorded in the system, can be by finished product batch or raw material batch number, the two-way product of reviewing; For the production run of each product, and the control situation of key link is all carried out the computing machine preservation; In traceability system, can carry out to the product of any one lot number the inquiry of database, if just arbitrary batch have underproof product to be recorded to and do not meet in the control;
1.9 do not meet control: set up and do not meet the control program form, namely when deviation appears in process, can not be improved to qualified product by corrective action, be classified as substandard product, and do not deal with to meeting product after isolating, analyzing;
The Real Time Monitoring of 2) food production data:
Computing machine carries out Real Time Monitoring for the data of food production line, key parameter for each link carries out Real Time Monitoring, utilize temperature sensor, timer, humidity sensor, weighing apparatus reacts real situation, and the data of feedback are communicated and be transferred to computing machine, computing machine is according to safe procedures and the hazard analysis of setting up before, judge whether the parameter that obtains satisfies its demand, and data are recorded in the database of computing machine, and send to Cloud Server by network, as data backup and storage, and the content that breaks the rules carried out alarm;
3) long distance control system of food production:
The Real Time Monitoring of food production, the data of monitoring are sent to Cloud Server, even not at production line, also can long-rangely carry out observation, the query contents of data.
Further, above-mentioned computer based food security, quality intelligent control method also comprise 4) the food security quality manual:
4.1 document control is divided into policy document, job specification file, log file with file, and the version of file is controlled, and each renewal of log file;
4.2 internal check: internal check also is part and parcel very in top HACCP examines, with the internal check process automation, three aspects: is mainly examined in internal check, it is the HACCP system, PRP system and the operation of implementing for reaching these, system is according to these three aspects, in the project of above foundation, screen, only filter out the title of project, generate an audit inventory, the form of inventory is general question, and inside auditor is examined system according to inventory, need only fill in and whether be, system stores and controls and analyze record according to the document control scheme that generates before, and computing machine also carries out data base administration to the record of storage, each link is preserved with the form of data, convenient later checking and reviewing;
4.3 the management of product, namely the product specification book is generated and Version Control automatically, model product specification book format, for the intelligent step of setting up of the specifications of each product be, computing machine reads product performance and purposes and the definite production procedure that the user inputs when the pre-step of hazard analysis, critical control point generates specifications automatically, and the user makes amendment according to actual needs, and the renewal of record specifications;
4.4 the control of product: new product development, set up the shelf-life and determine scheme database, for product type and corresponding shelf-life thereof are determined the set of method according to the product type of user's input, to provide shelf-life mensuration scheme to recommend.
Further, above-mentioned computer based food security, quality intelligent control method also comprise resource management foundation: set up personal management, resource management and infrastructure maintenance manager.
The substantive distinguishing features that technical solution of the present invention is outstanding and significant progressive being mainly reflected in:
The present invention adopts computer technology to help not have enough food manufacturers of high qualification food control expert personnel, in most scientific, state-of-the-art mode, to production safety, work of high quality from the planning that begins most to carry out in the contents such as actual production process monitoring and Long-distance Control supervision, the maintenance of food safety management system and renewal.Be mainly reflected in, can be in conjunction with requirement, Codex Committee on Food of the United Nations and other food standards of extensively approving of Chinese food production permit, intellectuality planning HACCP system, and can constantly update compromise data storehouse, PRP database, technological process database, process operation database.Utilize computing machine to make food security, quality control robotization.With reference to integrating the current food standard of extensively approving in the world for instructing, in conjunction with computing machine, at first food production is carried out the robotization planning, then the critical control point in producing is carried out robotization and control.Utilize cloud, the real-time update standard database instructs production rule, and utilizes up-to-date technology, guarantees the safety of food production.
Description of drawings
Below in conjunction with accompanying drawing technical solution of the present invention is described further:
Fig. 1: the schematic flow sheet of hazard Establishing;
Fig. 2: the schematic flow sheet of determining critical control point Raw CCP decision tree;
Fig. 3: the schematic flow sheet of determining process CCP decision tree in the critical control point.
Embodiment
Because existing food control solution can not provide all functions that meet the food control standard very perfectly, usually there is not to provide the function of expert decision-making, namely can not intelligently carry out the HACCP process, perhaps namely allow to carry out, but can not effectively upgrade, meet laws and regulations and the operation standard of the food industry on development internal and international.And at home especially neither one be fit to the solution that Chinese food manufacturer uses, namely help Chinese food manufacturer to obtain and safeguard production permit (QS), and production permit is the precondition that the food manufacturer can come into the market, and production permit needs the annual reexamination of all carrying out.
The invention provides a food manufacturer that can become China and meet total solution domestic, international standard.Be mainly reflected in, can in conjunction with the requirement of domestic product license, namely carry out the functional sequence that meets production permit; HACCP is carried out robotization, comprise and constantly update its compromise data storehouse, PRP database, technological process database, process operation database; The package management file of more integrating meets " food production Hygienic license examination general rule ", ISO22000 and BRC 6.0 standards.As long as with the logical relation of database, solution and the content of file management, become the mode of operation of computing machine, there be not under highly specialized personnel's the prerequisite the same operation instruction that can obtain specialty.
The idiographic flow of computer based food security, quality intelligent control method is as follows:
1) hazard Establishing (HACCP), as shown in Figure 1;
1.1 determining of the PRP of HACCP, namely set up the PRP database, based on (the Codex Alimentarius Commission of the international food code council, CAC), GMP (GMP) and SSOP(hygienic standard working specification), comprise that supplier controls, the safety of plant facilities plant maintenance, workshop layout, storage, public utilities (water of productive use, ice, air or other gas etc.), production environment cleaning and health, insect control, staffs training, employee's health, logistics, factory building, offal treatment etc.Relevant data-base content is stored in Cloud Server.And carry out management and the analysis of data classification.Each information is carried out the ID management, fixing numbering is arranged, when the change database, the data change record management of computing machine is arranged.Above scheme is divided into basic premise scheme and OPRP two classes, for routine call.
Supplier is controlled to be an important content in the PRP, comprises supplier audit, approval and supervision; Raw material and packing are checked and accepted and are monitored.The venture analysis that supplier's control is based on supplier draws, and this scheme realizes intelligent judgement with computer program.Method is that the process of risk assessment is quantized, and utilizes computing machine to determine degree of risk according to result of calculation and the result is carried out the supplier's of computing machine attribute management;
A. at first be raw material venture analysis flow process, according to the raw database screening, draw Risk list.Then each raw material is according to the possibility that occurs and two indexs of seriousness of harm, and each index is divided into 1,2,3 three level, and 1 is minimum, and 3 for the highest.The seriousness level of the possibility level of raw material risk=generation * harm is if the result who draws=9 or 6 then are excessive risk; If result=4 or 3 then are the moderate risk; If result=1 or 2 then are low-risk.
B. the program of supplier audit, approval and supervision depends on degree of risk that supplier supplies raw materials and supplier's itself the considering of risk size.After the raw material risk assessment is finished, carry out the risk assessment of supplier own, supplier's estimation flow, score is higher, and risk is larger, and assessment has 6 indexs, and each index has corresponding level:
A, whether Third Party Authentication is arranged, two levels of "Yes" and "No" are arranged, be=1; No=3;
The hardware facilities such as b, factory building, equipment have three levels, and three levels of " well " " qualified " " defective " are arranged, good=1; Qualified=2; Defective=3;
C, technician's strength, minute three levels, i.e. " good, " " qualified " and " defective ", good=1, qualified=2, defective=3;
D, product risks degree, minute " low ", " in ", " height " three levels; Low=1, in=2, high=3;
Whether e, scene have sensibiligen, minute two levels of "Yes" "No"; Be=3; No=1;
F, supplier be the immediate producer of raw material whether, is divided into "Yes", two levels of "No".
Risk score=(b+c+ d+e) * a, must being divided into of ideal situation: 4 minutes; If other conditions of supplier are all good, just not authentication then must be divided into 12 minutes, as the border of low-risk and risk; If the each side condition is all qualified, there is not Third Party Authentication, i.e. b, c, d each 2 minutes does not have sensitizer, and mark is 21 minutes, is risk and high risk border.Therefore: mark: 4～12 is low-risk, and 12～21 is the moderate risk, and 21～36 is excessive risk.No matter in any case, if index f is "No", then supplier is excessive risk simultaneously.
At last, according to the risk index that draws, decide the control measure to supplier: 1, all have the company of Third Party Authentication all will submit certificate of certification and the audit report of electronic edition.
Raw material and packing are checked and accepted and are monitored.The degree of risk that draws according to raw material is carried out the extraction result of high in the clouds database, operation indicating, and when the excessive risk raw material was checked and accepted, every batch all must have examining report, and range estimation when checking and accepting, moderate risk raw material is estimated during examination, and the random sampling detection, low risk raw material is estimated during examination.
1.2 the pre-step of hazard analysis: set up raw database, and raw material classifies according to character, these character are determining the potential hazard that raw material may carry;
Technological process of production Database: set up the technological process database, main reference is that country is to 28 based food production permit detailed rules and regulations, as the part of production permit.Database comprises 28 series products, and corresponding technological process, and when the user according to system suggestion inputted the finished product type, system just can read corresponding data from database, and the generating process process flow diagram.
The process steps Database: comprise manufacturing parameter commonly used, main reference is 28 based food production permit detailed rules and regulations and international food code council's standard and food technology technical manual, and each process steps comprises corresponding potential hazard and control measure.
The content that is based upon the computer logic relation in the database in advance, by client's selection itself and the content of actual conditions, carry out inner computer search and screening.And result's content feed to the user.
1.3 hazard analysis: computing machine, draws technological process and recommends behind the raw material and finished product of before input according to the user, then according to raw material and technological process, automatically generates potential hazard tabulation and control measure.The principle that control measure generate automatically is that system reads from the process steps database and endangers corresponding control measure, then according to flow process, filters out the optimum control measure that meets.Here computing machine also is to judge according to flow process and the logical relation determined in advance.Then, correspondence and each harm have two indexs, " possibility " and " seriousness " that namely occurs, each index has three levels, and three levels of " possibility " are " probably " (=3), " possibility " (=2) and " impossible " (=1); Three levels of " seriousness " are: " harmful " (=3); " dislike " (=2); Level=possibility level * seriousness level is then endangered, if income value in " unimportant " (=1)〉6, then be conspicuousness harm.
After all harm executed analysis, computing machine filtered out conspicuousness harm, and generated " significantly harm tabulation ".
1.4 the operability prerequisite is determined: control measure are classified, can not the quantification measure be OPRP, then but quantified controlling is further screened, filter out the control measure that are not included in the PRP database, draw " non-PRP control measure tabulation ", carry out next step process, namely critical control point is determined." non-PRP control measure tabulation " control measure in addition are then as OPRP, and computing machine generates " OPRP tabulation ".
1.5 determine critical control point (CCP), " the non-PRP control measure tabulation " that filters out more than the computing machine basis judged each raw material and process operation.
Should judge that for raw material to determine these raw materials of control of whether keeping under strict control during the course, deterministic process is also for answering 3 problems that answer is "Yes" and "No".Problem 1: whether this raw material has relevant harm, will if "Yes" then enters problem 2: you or client remove this harm if "No" then continue to analyze other raw material? if "No" then is sensitive raw material, highly control; If "Yes" then enters problem 3: out of contior cross-infection is arranged? if "No" then continues to analyze other raw materials, if "Yes" then is sensitive raw material, highly control.Deterministic process as shown in Figure 2.
Then, the process operation is judged that determination methods is comprised of 5 problems, to each question answering "Yes" and "No", process is as follows: problem 1: is there harm in this step? if "No" then is not CCP; Can if "Yes" then enters lower problem 2: this harm be controlled? is if the answer "No" is then answered a question: controlling in this step to guarantee that safety is necessary? if "No" then is not CCP, if "Yes", then modification and processing operation or product; If problem 2 is answered "Yes", is is then enter problem 3: this operation used for especially eliminating harm or harm reduced to acceptable level? if "Yes" is CCP, if "No" enters problem 4: might occur to pollute or endanger to be increased to and to accept level? if "No" then be not CCP, is does if "Yes" then enter problem 5: the trade union that adds afterwards eliminate risk or it reduced to acceptable level? if "Yes" then be not CCP, if "No" then after to be CCP. by above logic judge, computing machine filters out CCP, generate the CCP tabulation, then in process steps, screen, supervisory programme and Key Limit Value that output meets, and corrective action, and generation tabulation, according to the definite CPP control case in the database in the production procedure that automatically generates, carry out basic CPP reference mark in addition.Deterministic process as shown in Figure 3.
1.6 HACCP confirms that computing machine is invoked at the HACCP plan of producing in the step 1.5, calculates the plan that generates before looking back.
Whether 1.7 HACCP verifies planning: make a plan, verify that HACCP plans in actual production, effectively carry out, the planning of checking comprises audit production run record, internal check, finished product test, Customer Complaint record and trend analysis.
1.8 trackability system made: set up finished product batch scheme, if the lot number of 3 kinds of forms is arranged, according to client's practical condition, the date of the minimum degree of accuracy of permission for producing.Namely, according to batch number of producing in a day of family input, if system recommendation batch number form is a collection of, then batch number is date or its corresponding number, if produced more than a collection of in one day, then the batch number form of system recommendation is added a numeral, represents certain batch in a day, if each batch has many machines to finish, then batch form of system's generation is added one digit number again, and every machine has corresponding numeral, separates with separator bar in the middle of the numeral; Set up raw material batch number, the bar code that the raw material of every batch every kind warehouse-in is all produced by system, give specific lot number, when putting into production, scanning bar code, record the used raw material batch of certain batch products, if when producing semi-manufacture with raw material, use and same mode, come mark with bar code, when putting into production, by scanning to record batch.Finished product batch can with the raw material that uses or half-finished batch and relevant critical control point monitor record on same form, be recorded in the system.Can by finished product batch or raw material batch number, come the two-way product of reviewing.For the production run of each product, and the control situation of key link is all carried out the computing machine preservation.In traceability system, can carry out to the product of any one lot number the inquiry of database, if just arbitrary batch have underproof product to be recorded to and do not meet in the control.
1.9 do not meet control: set up and do not meet the control program form, namely when deviation appears in process, can not be improved to qualified product by corrective action, be classified as substandard product, and isolate, analyzed by the related personnel and then do not deal with to meeting product.
The Real Time Monitoring of 2) food production data:
Computing machine carries out Real Time Monitoring for the data of food production line, carries out Real Time Monitoring for the key parameter of each link.Utilize temperature sensor, timer, humidity sensor, weighing apparatus etc. react real situation, and the data of feedback are communicated (serial ports, USB or Ethernet) and are transferred to computing machine.Computing machine judges according to safe procedures and the hazard analysis of setting up before whether the parameter that obtains satisfies its demand.And data are recorded in the database of computing machine, and send to Cloud Server by network, as data backup and storage.And the content that breaks the rules carried out alarm.
3) long distance control system of food production
Because the Real Time Monitoring of food production, the data of monitoring can be sent to Cloud Server, so even not at production line, account that also can Telnet oneself is carried out the observation of data, the contents such as inquiry.
4) food security quality manual:
4.1 document control, system is divided into policy document, job specification file, log file with file, and the version of file is controlled.
4.2 internal check: internal check also is part and parcel very in top HACCP examines.With the internal check process automation, three aspects: is mainly examined in internal check, i.e. HACCP system, PRP system and the operation implemented for reaching these.System screens in the project of above foundation according to these three aspects, only reads its title, generate an audit inventory (check list), the form of inventory is general question, and inside auditor can be according to inventory, system is examined, need only fill in "Yes" and "No".System stores and controls and analyze record according to the document control scheme that generates before.Here computing machine also carries out data base administration to the record of storage, and each link is preserved with the form of data, convenient later checking and reviewing.
4.3 the management of product namely generates and Version Control automatically to the product specification book.Model product specification book format.For the intelligent step of setting up of the specifications of each product be, computing machine reads product performance and purposes and the definite production procedure that the user inputs when the pre-step of 2.1.2 hazard analysis, critical control point etc. generate specifications automatically, and the user can make amendment according to actual needs.
4.4 the control of product: new product development, set up the shelf-life and determine scheme database, determine the set of method for the shelf-life of product type (being cold bright product, quick frozen product and preservation under room temperature product three classes) and correspondence thereof.According to the product type of user's input, provide shelf-life mensuration scheme to recommend.
5) resource management is set up: on the basis that top management is promised to undertake, set up personal management, resource management, and infrastructure maintenance manager.
During concrete the application, such as a milk products plant of preparing, plant and equipment are all purchased, and next need to set up the food security quality management system.Food industry standard universal PRP at first is provided, to supplier control, needs raw material that input supplier provides and above-mentioned supplier's index, computer program just can be calculated supplier's risk index, and lists control program.
Afterwards, the user inputs raw material, i.e. milk, and then system just can provide a potential hazard that raw material milk is entrained.Because be pasteurization milk, institute thinks refrigeration.Afterwards, system can export the flow process chart of recommendation.After the affirmation, program calculates corresponding potential hazard tabulation, and lists, and comprises the harm in raw material harm and the process.According to s own situation, the user is by prompting, input the seriousness of each harm and the possibility of generation, then calculate conspicuousness, and the Auto-matching control measure, list conspicuousness harm and control measure tabulation, then program filters out the control measure of non-operational PRP, and corresponding harm, output harm, manufacturing procedure and control measure tabulation.
Then enter the critical control point deterministic process.The user in the light of actual conditions, input "Yes" and "No", computing machine is according to the answer of input, then whether be CCP (critical control point) to program if just can calculate specific operation.
At last, system's output CCP tabulation.After database screening and coupling, corresponding Key Limit Value, supervisory programme, corrective action just can be recommended by system, and then the user only needs just can according to the actual name of inserting the responsible official.Afterwards, the user just according to the plan of output, confirms.Afterwards, the checking planning just can be recommended by system, and worksheet is provided, for being used for recording the monitoring process parameter in user's actual production.Then the user inputs production batch every day, and system just provides the product back-tracing program, and does not meet control program, and after the user confirmed, whole HACCP planning was just finished.
After the HACCP planning was finished, computing machine meeting guides user enters set up food security and quality manual function.Program generating recommendations File Control Procedure, after the user confirms, organization chart and the job description of before user's input, and program file and the task instruction of all departments also all can be kept at corresponding position in this functional module.Then, just enter next step internal check.Examine program and flow process in the computer recommending, namely the interior content of examining comprises inventory, and the user need only check, confirms after the satisfaction to get final product.Afterwards, system just can draw according to the interior audit of setting, and examines in the reminding user.Then be to enter material supplier's administration module.After the user inputs the most basic information, just can obtain the material supplier and carry out venture analysis, and obtain the system recommendation Managed Solution, get final product after the affirmation, in addition, because milk is agricultural product, computing machine also can be according to GAP (GAP), recommend its milk-supply merchant is managed and technology is recommended accordingly to the user, control better the milk-supply merchant in the operation in farm stage, thereby guarantee better the quality of raw material milk.
The management of product and control afterwards, the information of user's input and the result who calculates before the computing machine basis, automatic production product specification book, the user just is kept at corresponding position after confirming approval.The computer guidance user sets up procedures of new product development afterwards, and the resource management supervisor, and in addition, computing machine can be advised to user's workshop layout according to user's product, comprises the isolation in high risk area and low-risk district, insect control etc.
After all programs established, system just can generate an index, makes things convenient for the user search All Files.After establishing above system, just the user can apply for QS license, if according to as above process, just can smoothly by audit, put into production.
After the user enters actual production, according to the HACCP plan of planning, production run is monitored, the data of feedback are carried out Computer Analysis, and had the part of harm to carry out early warning, the contents such as alarm to the result of analysis.The data of storage can be carried out long-range checking simultaneously.And regularly carry out interior examining with HACCP and verify.The interior result who examines also can contact to HACCP authentication module, when the user carries out the HACCP checking, and the fruit of concluding in just can easily being deployed into.Simultaneously, at the HACCP authentication module, contact record of production and finished product detection record, customer complaint record and analysis etc., the user just can see the information that all are used for verifying HACCP at a glance.In addition, if the user is the manufacturer that has moved, and so that the system of oneself to be arranged, then can the above method of choice for use rebulid, compare with existing system, perhaps can also directly import existing, improve existing system in order to upper method, and it is safeguarded.
In sum, the present invention adopts computer technology to help not have enough food manufacturers of high qualification food control expert personnel, in most scientific, state-of-the-art mode, to the product of production safety from beginning most to plan the contents such as production process monitoring and Long-distance Control supervision, the maintenance of food safety management system and renewal.Be mainly reflected in, intellectuality planning HACCP system, and can constantly update compromise data storehouse, PRP database, production technology database; More with reference to and integrated the standard of " food production Hygienic license examination general rule (version in 2010) ", ISO22000 and BRC 6.0, the intelligent formulation and the maintenance system document control, and can meet the requirement of " food production Hygienic license examination general rule ", ISO22000 and BRC 6.0 standards, and can constantly update the food standard database, make it the field of food industry that meets better continuous renewal, changes.
Utilize computer technology to realize food security, quality control robotization.With reference to integrating the current food standard of extensively approving in the world for instructing, in conjunction with computing machine, at first food production is carried out the intellectuality planning, then the critical control point in producing is carried out robotization and control.Utilize cloud, the real-time update standard database instructs production rule, and utilizes up-to-date technology, guarantees the safety of food production.
What need to understand is: the above only is preferred implementation of the present invention; for those skilled in the art; under the prerequisite that does not break away from the principle of the invention, can also make some improvements and modifications, these improvements and modifications also should be considered as protection scope of the present invention.
Claims (3)
1. computer based food security, quality intelligent control method is characterized in that may further comprise the steps:
1) hazard HACCP Establishing:
1.1 determining of the PRP of HACCP, namely set up the PRP database, based on " food production Hygienic license examination general rule " and with and the detailed rules and regulations of 28 based foods that comprise, the CAC of Codex Committee on Food of the United Nations, GMP GMP and hygienic standard working specification SSOP, comprise that supplier controls, the plant facilities plant maintenance, the workshop is arranged, storage, public utilities, production environment cleaning and health, insect control, staffs training, employee's health, logistics, the safety of factory building, offal treatment, store data-base content into Cloud Server, and carry out management and the analysis of data classification, each information is carried out the ID management, fixing numbering is arranged, when the change database, the data change record management of computing machine is arranged, scheme is divided into basic premise scheme and OPRP two classes;
Supplier is controlled to be an important content in the PRP, comprise supplier audit, approval and supervision, raw material and packing are checked and accepted and are monitored, supplier's control is based on supplier's venture analysis is drawn, the process of risk assessment is quantized, utilize computing machine to determine degree of risk according to result of calculation and the result is carried out the supplier's of computing machine attribute management;
A. at first be raw material venture analysis flow process, according to the raw database screening, draw Risk list, then each raw material is according to the possibility that occurs and two indexs of seriousness of harm, and each index is divided into 1,2,3 three level, and 1 is minimum, 3 for the highest, the seriousness level of the possibility level of raw material risk=generation * harm is if the result who draws=9 or 6 then are excessive risk, if result=4 or 3, then be the moderate risk, if result=1 or 2 then are low-risk;
B. the program of supplier audit, approval and supervision, the considering of risk size that depends on degree of risk that supplier supplies raw materials and supplier itself, after the raw material risk assessment is finished, carry out the risk assessment of supplier own, supplier's estimation flow, score is higher, and risk is larger, assessment has 6 indexs, and each index has corresponding level:
A, whether Third Party Authentication is arranged, have whether to be two levels, be=1, no=3;
B, factory building, device hardware facility have good, qualified, defective three levels, good=1, qualified=2, defective=3;
C, technician's strength, minute good, qualified, defective three levels, good=1, qualified=2, defective=3;
D, product risks degree, minute basic, normal, high three levels, low=1, in=2, high=3;
Whether e, scene have anaphylactogen, minute are, no two levels, be=3, no=1;
F, supplier be the immediate producer of raw material whether, minute is, no two levels;
Risk score=(b+c+ d+e) * a, must being divided into of ideal situation: 4 minutes, if other conditions of supplier are all good, just not authentication then must be divided into 12 minutes, as the border of low-risk and risk; If the each side condition is all qualified, there is not Third Party Authentication, namely b, c, d are each 2 minutes, do not have sensitizer, and mark is 21 minutes, is risk and high risk border; Therefore: mark: 4～12 is low-risk, and 12～21 is the moderate risk, and 21～36 is excessive risk, no matter in any case, if index f is no, then supplier is excessive risk simultaneously;
At last, according to the risk index that draws, determine the control measure to supplier: all have Third Party Authentication all will submit certificate of certification and the audit report of electronic edition;
Raw material and packing are checked and accepted and are monitored, the degree of risk that draws according to raw material is carried out the extraction result of high in the clouds database, operation indicating, when the excessive risk raw material was checked and accepted, every batch all must have examining report, and range estimation when checking and accepting, moderate risk raw material is estimated during examination, and random sampling detects, low risk raw material is estimated during examination;
1.2 the pre-step of hazard analysis: set up raw database, and raw material classifies according to character, character is determining the potential hazard that raw material may carry; After the user inputted raw material, computing machine just read and exports corresponding potential hazard and points out;
Technological process of production database: set up the technological process database, be referenced as country to 28 based food production permit detailed rules and regulations, part as production permit, database comprises 28 series products and corresponding technological process thereof, when the user according to system suggestion inputs the finished product type, just from database, read corresponding data, and the generating process process flow diagram;
Process operation database: this database is with reference to 28 based food production permit detailed rules and regulations and international food code council's standard and food technology technical manual etc., formulate relevant production procedure for different production products, and can make amendment to flow process according to client's demand; Each process operation comprises corresponding manufacturing parameter, the potential hazard that may introduce, eliminable potential hazard, control measure and corresponding corrective action and Key Limit Value; The corresponding production procedure database of each operation in this database;
With being based upon the content of the computer logic relation in the database, by client's selection itself and the content of actual conditions, carry out the inner computer search and screen, and result's content feed to the user;
1.3 hazard analysis: behind the raw material and finished product that computing machine provides according to the user, drawing technological process recommends, then according to raw material and technological process, automatically generate potential hazard tabulation and control measure, the principle that control measure generate automatically is that computer system reads from process operation database and endangers corresponding control measure, then according to flow process, filter out the optimum control measure that meets, computing machine also is to judge according to flow process and the logical relation determined in advance; Then, corresponding to each harm, two indexs are arranged, the possibility and the seriousness that namely occur, each index has three levels, and three levels of possibility are for probably=3, possible=2, impossible=1; Three levels of seriousness are: harmful=3, dislike=2, level=possibility level * seriousness level is then endangered, if income value in unimportant=1〉6, then be conspicuousness harm;
After all harm executed analysis, computing machine filtered out conspicuousness harm, and generated significantly harm tabulation;
1.4 the operability prerequisite is determined: control measure are classified, can not the quantification measure be OPRP, then but quantified controlling is further screened, filter out the control measure that are not included in the PRP database, draw non-PRP control measure tabulation, carry out next step process, namely critical control point is determined, control measure in addition are then as OPRP but not the PRP control measure are tabulated, and computing machine generating run PRP is tabulated;
1.5 determine critical control point CCP, the non-PRP control measure tabulation that filters out more than the computing machine basis is judged each raw material and process operation;
Should judge that for raw material to determine these raw materials of control of whether keeping under strict control during the course, deterministic process is for answering 3 problems that answer is "Yes" and "No"; Problem 1: whether this raw material has relevant harm, will if "Yes" then enters problem 2: you or client remove this harm if "No" then continue to analyze other raw material? if "No" then is sensitive raw material, highly control; If "Yes" then enters problem 3: out of contior cross-infection is arranged? if "No" then continues to analyze other raw materials, if "Yes" then is sensitive raw material, highly control;
Then, per pass process operation is judged that determination methods is comprised of 5 problems, to each question answering "Yes" and "No", process is as follows: problem 1: is there harm in this step? if "No" then is not CCP; Can if "Yes" then enters lower problem 2: this harm be controlled? is if the answer "No" is then answered a question: controlling in this step to guarantee that safety is necessary? if "No" then is not CCP, if "Yes", then modification and processing operation or product; If problem 2 is answered "Yes", is is then enter problem 3: this operation used for especially eliminating harm or harm reduced to acceptable level? if "Yes" is CCP, if "No" enters problem 4: might occur to pollute or endanger to be increased to and to accept level? if "No" then be not CCP, is does if "Yes" then enter problem 5: the trade union that adds afterwards eliminate risk or it reduced to acceptable level? if "Yes" then be not CCP, if "No" then be CCP; After above logic judgement, computing machine filters out CCP, generates the CCP tabulation, then screens supervisory programme and Key Limit Value that output meets, and corrective action, and generation tabulation in process steps; According to the definite CPP control case in the database in the production procedure that automatically generates, carry out basic CPP reference mark in addition;
1.6 HACCP confirms that computing machine is invoked at the HACCP plan that produces in the step 1.5, calculates the plan that generates before looking back;
Whether 1.7 HACCP verifies planning: make a plan, checking HACCP plans in actual production, effectively carry out, and the planning of checking comprises audit production run record, internal check, finished product test, Customer Complaint record and trend analysis;
1.8 trackability system made: set up finished product batch scheme, the lot number that 3 kinds of forms are arranged, practical condition according to the client, the date of the minimum degree of accuracy that allows for producing, namely, according to batch number of producing in a day of family input, if system recommendation batch number form is a collection of, then batch number is date or its corresponding number, if produced more than a collection of in one day, then the batch number form of system recommendation is added a numeral, represents certain batch in a day, if each batch has many machines to finish, then batch form of system's generation is added one digit number again, and every machine has corresponding numeral, separates with separator bar in the middle of the numeral; Set up raw material batch number, the bar code that the raw material of every batch every kind warehouse-in is all produced by computer system, give specific lot number, when putting into production, scanning bar code, record the used raw material batch of certain batch products, if when producing semi-manufacture with raw material, use and same mode, come mark with bar code, when putting into production, by scanning to record batch, finished product batch can with the raw material that uses or half-finished batch and relevant critical control point monitor record on same form, be recorded in the system, can be by finished product batch or raw material batch number, the two-way product of reviewing; For the production run of each product, and the control situation of key link is all carried out the computing machine preservation; In traceability system, can carry out to the product of any one lot number the inquiry of database, if just arbitrary batch have underproof product to be recorded to and do not meet in the control;
1.9 do not meet control: set up and do not meet the control program form, namely when deviation appears in process, can not be improved to qualified product by corrective action, be classified as substandard product, and do not deal with to meeting product after isolating, analyzing;
The Real Time Monitoring of 2) food production data:
Computing machine carries out Real Time Monitoring for the data of food production line, key parameter for each link carries out Real Time Monitoring, utilize temperature sensor, timer, humidity sensor, weighing apparatus reacts real situation, and the data of feedback are communicated and be transferred to computing machine, computing machine is according to safe procedures and the hazard analysis of setting up before, judge whether the parameter that obtains satisfies its demand, and data are recorded in the database of computing machine, and send to Cloud Server by network, as data backup and storage, and the content that breaks the rules carried out alarm;
3) long distance control system of food production:
The Real Time Monitoring of food production, the data of monitoring are sent to Cloud Server, even not at production line, also can long-rangely carry out observation, the query contents of data.
2. according to claim 1 described computer based food security, quality intelligent control method is characterized in that: also comprise the food security quality manual:
4.1 document control is divided into policy document, job specification file, log file with file, and the version of file is controlled, and the renewal of log file;
4.2 internal check: internal check is part and parcel very in top HACCP examines, with the internal check process automation, three aspects: is mainly examined in internal check, it is the HACCP system, PRP system and the operation of implementing for reaching these, computing machine is according to these three aspects, in the project of above foundation, screen, filter out the title of project, generate an audit inventory, the form of inventory is general question, and inside auditor is examined system according to inventory, need only fill in and whether be, system stores and controls and analyze record according to the document control scheme that generates before, and computing machine also carries out data base administration to the record of storage, each link is preserved with the form of data, convenient later checking and reviewing;
4.3 the management of product, namely the product specification book is generated and Version Control automatically, model product specification book format, for the intelligent step of setting up of the specifications of each product be, computing machine reads product performance and purposes and the definite production procedure that the user inputs when the pre-step of hazard analysis, critical control point generates specifications automatically, and the user makes amendment according to actual needs, and the renewal of record specifications;
4.4 the control of product: new product development, set up the shelf-life and determine scheme database, for product type and corresponding shelf-life thereof are determined the set of method, according to the product type of user's input, computing machine provides shelf-life mensuration scheme to recommend.
3. computer based food security according to claim 1, quality intelligent control method is characterized in that: also comprise resource management foundation: set up personal management, resource management and infrastructure maintenance manager.
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