Fermente süt ürünlerinde hata modu ve etki analizleri (FMEA)

Fermented dairy products are the major part of the diet in Turkey. Controlling the risks effectively by selecting and implementing appropriate measures during the production is very important since this measures increase the quality of food products, protect the public health and consumer?s trust. In onsite visits, it has seen that prevailing food safety programs might not be sufficient to control the potential hazards during processing. Failure Mode and Effect Analysis (FMEA) is a widely used tool for quality assurance in many manufacturing industries, addressing customer and governmental requirements, quality control and safety. In this study, FMEA methodology has been applied for the risk assessment of yogurt, ayran, kefir, dil cheese, plaited cheese, kashar cheese, cultured white cheese, and traditional white cheese productions. The process flow diagrams for production of the selected dairy foods are constructed based on the most common processes observed during onsite visits to 30 different dairy producing companies in different regions of Turkey. Possible failure modes in the process are identified and the potential hazards for each failure mode are analyzed. The Risk Priority Numbers (RPN) were calculated from multiple of three variables; frequency of occurrence (O) for each failure, seriousness of the failure (S), and possibility of detecting the failure (D); to identify the risk level of each potential failure. Possible corrective actions are suggested for each potential failure mode with risk priority numbers higher than 100. At these points, the RPNs are recalculated to understand the influence of corrective actions on the improvement of the process. The highest total RPN values are calculated for raw material receiving filling/packaging, dry matter adjustment, resting in brine, dry blanching and blanching in water steps in dairy food processes. Improper hygiene, staff practices and cleaning operations are found to be the basic reasons for failure modes. Implementation of FMEA methodology in dairy food manufacturing reduced the RPNs by 81-82% and therefore improved the safety and quality of final products for all processes.