Effectiveness of 5S Application in Tea Industry and Synchronization of 5S into ISO 22000:2005

A study was conducted to develop an ISO 22000 generic model for tea industry in synchronization with 5S while considering changes in currently adapted systems, processes, practices and adaptation to design synergetic technical solutions. Thus all stakeholders in tea manufacturing process were interviewed and requested to use the developed documents as a user innovation strategy and incorporated progressive changes in design until both document management and user’s requirements were satisfied. The documents were prepared in local language and 5S work instructions were enriched with food hygiene requirements instead of developing new set of instructions where harmonization, modification and adaptation was very effective. Work instructions, cleaning and housekeeping were further integrated while enriching with relevant standards to be met after cleaning as well as relevant records and references. Consequently, work instructions, preventive maintenance, general housekeeping, training and standardization were properly synchronized where it was used from existing 5S systems with modifications to harmonize and comply with ISO 22000 as well as 5S requirements which reduced the time spent for recordings on two systems. Synchronization reduced the number of documents used in the food safety management system up to a great extent and frequency of recording while improving the effectiveness of recording.