Gunawardeana - Dairy - Sri Lanka

Manjula Gunawardeana

Sri Lanka

Services

Dairy

Work History

Head of Quality

JUBILANT FOODWORKS LANKA LTD (DOMINO’S PIZZA)

From December 2012

 Main Products: Pizza, Chocó lava, Pasta, garlic Bread, Calzone etc.

Responsible for ensuring the right quality of the all incoming raw materials and
Packing materials as well as for semi-finished and finished goods at all regional commissaries.
Develop, implement, and maintain a quality plan to bring company's Quality Management Systems and Policies into compliance with various quality system requirements. To achieve HACCP, ISO 9001/22000 or relevant certification for 550 stores.
Ensuring the right GHP, GMP in all commissary and stores across the region.
Responsible for handling product's quality complaints at corporate level.
Monthly store audit.
Ensuring the compliance of the various parameters points as per Commissary Check List.
Ensuring Backend Commissary to follow the international norms and the national vendors follow the same guidelines.
Generating MIS out of Monthly QA Score Card, Store Audit, Commissary Audit on International Format, Weekly QA Report(Customer Complaints), Monthly Departmental Update etc.
Follow up with vendor and purchase team regarding any deviation from specs/quality in the raw and packing materials.
Ensuring the proper and effective implementation of the SOPs for production, quality and handling, packing during New Product Launch
Training Commissary (Central kitchen) and Outlets staff regards HAACP/ISO 22000

Lab Analyst

NESTLE DUBAI MANUFACTURING LLC, DUBAI, UAE

From August 2010

o Handling of NQMS, , ISO 22000, NGMP, SOPs for NIDO and KITKAT Plant
 Guiding Nestle Quality Monitoring Scheme (NQMS)
 Ensure personnel disciplines, zoning and related document and information
Personnel disciplines -Shoe Cover Concepts.
-Hand Washing.
-Hand Sanitizing.
-Uniforms
-Hair Nets
-Safety Shoes.
-Personnel Protective Equipment (PPE).
-Jewellery Policy
Handling of Zoning -Ensuring machine cleaning and sanitizing by dry cleaning of every machine and equipment (Vacuum cleaners).
-Ensuring cleaning and disinfection of zoning
High hygiene area of the plant.
Medium hygiene area of the plant.
Basic hygiene area of the plant.
Validation of effectiveness and efficiency of cleaning inside the zoning and Line Change Over.
Controlling the foreign body.
Updating KPI’s boards.
Creating One Point lesson(OPL), Escalated Issues and Standard Routines
Solving problems by using Problem Solving Tools
-Fish Bone Analysis (FBA).
-Go See Think and Do (GSTD).
-Define, Improve, Measure, Analysis, Control
(DIMAC).
 Guiding of ISO 22000 Food Safety Management System
 Ensure and Verification of Critical Control Points (CCP’s)
Safe line Metal Detectors and X Ray metal detectors.
 Ensure and Verification of Operational Pre Requisite Programme (OPRP’s)
Tins Flushing Ionized air systems and blower running.
 Ensure Pre Requisite Programme (PRP’s)
Personnel Hygiene.
Pest control systems monitoring and controlling.
 Ensure Control Points (CP’s)
Seaming and sealing of the final Products.
 Ensure Product Compliance

NESTLE DUBAI MANUFACTURING LLC

August 2010 - October 2012

Brief about Nestle Dubai manufacturing LLC, (NDM):
Nestle, the world's leading nutrition, health, wellness and the largest food company, founded and headquartered in Vevey, Switzerland. NDM is manufacturing powdered milk, KitKat and package imported Mackintosh's Quality Street chocolates by implementing NQMS/ISO
22000, ISO 14000 and OHSAS 18001.
➢ Main Products: Milk Powder(NiDO 1+,3+, FCMP, Carnation, KLIM), KITKAT
* Post: Food Chemist
Roles:
o Handling of NQMS, , ISO 22000, NGMP, SOPs for NIDO and KITKAT Plant
➢ Guiding Nestle Quality Monitoring Scheme (NQMS)
❖ Ensure personnel disciplines, zoning and related document and information
• Personnel disciplines -Shoe Cover Concepts.
-Hand Washing.
-Hand Sanitizing.
-Uniforms
-Hair Nets
-Safety Shoes.
-Personnel Protective Equipment (PPE).
-Jewellery Policy
• Handling of Zoning -Ensuring machine cleaning and sanitizing by dry cleaning of every machine and equipment (Vacuum cleaners).
-Ensuring cleaning and disinfection of zoning
• High hygiene area of the plant.
• Medium hygiene area of the plant.
• Basic hygiene area of the plant.
• Validation of effectiveness and efficiency of cleaning inside the zoning and Line Change Over.
• Controlling the foreign body.
• Updating KPI's boards.
• Creating One Point lesson(OPL), Escalated Issues and Standard Routines
• Solving problems by using Problem Solving Tools
-Fish Bone Analysis (FBA).
-Go See Think and Do (GSTD).
-Define, Improve, Measure, Analysis, Control
(DIMAC).
• Training on Nestle quality Tools
[Goal Alignment, One Model, Centre lining, Total Performance Management (TPM), Operational Master planning (OPM), Help Chain, PQCDSM (Productivity, Quality, Cost , Delivery, Safety, Moral)].
• Ensuring Shift hand over in accordance NCE by considering Safety, Quality, Compliance & Due Actions, Tasks, Endorsements, Priority Actions.
➢ Guiding of ISO 22000 Food Safety Management System
❖ Ensure and Verification of Critical Control Points (CCP's)
• Safe line Metal...

Lab Technician

ARABIAN BEVARAGE COMPANY LTD, KUWAIT

July 2008 - June 2010

o Inspection of online activities and evaluation of the same onsite production.
o To carry out the predetermined range of Chemical, Physical and Organoleptical
test required to monitor quality parameter from raw material to finished product as per the Combibloc standards.
o Microbiological analysis of raw materials and finished products according to
GCC parameters.
o Evaluation of set parameters before start of filling machines in accordance to the
Combibloc standards.
o CIP and sterilization records for filling lines and UHT sterilizers.
o Hourly sampling and online physical analysis for final package and highlighting
issues to the QA Manager.
o GMP and sanitation monitoring over processing area and filling area.
o Routine inspection of processing and filling area and break down issues.
o Assisting in on-lab activities at emergencies.
o Reporting non-conformance or deviation of prescribed packing standard to the
QA Manager for further decision and actions.
o Control of Hold products and Rejected products as per In-house procedures.
o Sampling activities in case of unsterilities and sterile tests.
o Fat and Moisture analysis of Dairy Products.
o Density analysis by using Anton Paar density meter.
o Viscosity analysis by using Brookfield Viscosity Meter Model TC-102.
o Total Solid analysis by using Halogen Moisture Analyzers (METTLER TOLEDO Meter).
o Analysis of processing water, Machine sterility and Air sterility etc.
o Ensure that lab activities are carried out according to Safety, Hygiene, Housekeeping,
quality standards and Monitoring of personnel and factory hygiene.
o Carry out Calibration of lab equipment at regular interval as per work instruction.
o Prepared and implement ISO and GMP quality procedures and liaison with
internal ISO auditors to keep the standard of the factory according to ISO quality
standard.



Production Executive

SCAN Products Division of C.W. Mackie PLC, Sri Lanka

April 2008 - August 2008

o Monitoring quality of all products - Raw materials, Packing materials
o Evaluation of set parameters before start of filling machines(BRIX, Ph, CL2 level,
Fe+ Concentration, Acidity and Hardness of process water).
o Implementation of ISO systems and maintain all documentation.
o Conducting quality audits and initiating actions in anticipation of quality
problems.
o Formulating and implementing quality and safety awareness programs in the
factory.
o Inspection of personnel hygiene and Sanitation.
o Production planning according to market demanding.

Quality Control Inspector

ARABIAN BEVARAGE COMPANY LTD

July 2008 - July 2010

KUWAIT. (July 2008 to 2010 July)
Brief about ABC, Kuwait:
ABC is the second largest food manufacturing company in Kuwait. ISO 9001:2000 and GMP systems have been implemented and manufacturing more than 25 varieties of dairy and fruit juice products by using modern technologies (APV, GEA, KF pasturizers, UHT, Homoginzer as well as SIG combibloc packaging materials and filling machines) for exporting Gulf reagent.
➢ Main Products: Dairy and Fruit Juices
* Post: Quality Control Inspector
Roles:
o Inspection of online activities and evaluation of the same onsite production.
o To carry out the predetermined range of Chemical, Physical and Organoleptical
test required to monitor quality parameter from raw material to finished product as per the Combibloc standards.
o Microbiological analysis of raw materials and finished products according to
GCC parameters.
o Evaluation of set parameters before start of filling machines in accordance to the
Combibloc standards.
o CIP and sterilization records for filling lines and UHT sterilizers.
o Hourly sampling and online physical analysis for final package and highlighting
issues to the QA Manager.
o GMP and sanitation monitoring over processing area and filling area.
o Routine inspection of processing and filling area and break down issues.
o Assisting in on-lab activities at emergencies.
o Reporting non-conformance or deviation of prescribed packing standard to the
QA Manager for further decision and actions.
o Control of Hold products and Rejected products as per In-house procedures.
o Sampling activities in case of unsterilities and sterile tests.
o Fat and Moisture analysis of Dairy Products.
o Density analysis by using Anton Paar density meter.
o Viscosity analysis by using Brookfield Viscosity Meter Model TC-102.
o Total Solid analysis by using Halogen Moisture Analyzers (METTLER TOLEDO Meter).
o Analysis of processing water, Machine sterility and Air sterility etc.
o Ensure that lab activities are carried out according...

Quality Assurance, Research and Development division of MILCO Private Limited

January 2008 - April 2008

Main Products: Dairy (Butter, yoghurt, Ice Cream and Drinking Milk)

o Fat determination in fresh Milk.
o Solid-non -fat determination in milk - density hydrometer method.
o Alcohol precipitation Test.
o Clot on boiling test.
o Keeping quality test- Resazuring Test.
o Determination of titrable Acidity of Milk.
o Detection of hydrogen peroxide in Milk.
o Estimation of residual hydrogen peroxide in Milk.
o Determination of Sucrose in milk- Cayaux's Method.
o Detection of starch in Whole milk.
o Detection of Skim Milk powder in Whole milk.
o Methyle Blue Reduction (MBR) test.
o Moisture, Fat, salt, Free fatty acid testing in Butter, yoghurt, Ice Cream and drinking milk.
o Milk Powder test method:
* Moisture test
* Insolubility index test
* Scorch Particles Test
* Fe2O3 test
* Acidity test
* Fat % determination test
* Organoleptic test

Quality Controller

Uva Fruit Cannery & Food Products , Sri Lanka

September 2006 - March 2008

o Daily audit of sanitation activities including pre and post cleaning equipment inspection.
o Daily write-up of the cleaning inspection results and corrective actions
o Daily audits of production procedures including; verification of code dates, scales, water levels, plant GMP’s, and documentation
o Sample collection, operation of lab equipment, data analysis and entry, shipment of sample.
o Analytical testing of raw and finished products as well as processing water
o Examine product retain shelf life samples.
o Ensuring the parameters are followed for various products as per the rules and standards of the regulatory authorities
o Attending to the trouble shooting related to quality of the product
o Maintaining the cleanliness and hygiene of the production facility and conducting the Quality Audit of the factory

Quality management

SCAN Products Division of C.W. Mackie PLC

September 2006 - July 2008

Sri Lanka
(September 2006 to July 2008)
Brief about SCAN, Sri Lanka.
SCAN is manufacturing Sunquick squash concentrate Fruit Juices and Water bottling under the supervision of CO-RO FOOD A/S, Denmark for local market by fulfilling ISO 9001:2000 Quality management system.

➢ Main Products: Fruit Juices, Process Water
* Post: Production Executive
Roles:
o Monitoring quality of all products - Raw materials, Packing materials
o Evaluation of set parameters before start of filling machines(BRIX, Ph, CL2 level,
Fe+ Concentration, Acidity and Hardness of process water).
o Implementation of ISO systems and maintain all documentation.
o Conducting quality audits and initiating actions in anticipation of quality
problems.
o Formulating and implementing quality and safety awareness programs in the factory.
o Inspection of personnel hygiene and Sanitation.
o Production planning according to market demanding.


Knowledge of Certification Systems
* OHSAS 18001 (Lead Auditor)
* ISO 22000/HACCP
* GOOD MANUFACTURING PRACTICES (GMP)
* GOOD HOUSE KEEPING PRACTISES (GHP)
* ISO 9001:2000
* ISO 17025:2005

TEA RESEARCH INSTITUTE

April 2006 - August 2006

Implement HACCP System in Orthodox Tea Manufacturing Industry
➢ Main Products: Tea

o Prepared HACCP Manual and related documents.
o Implemented HACCP quality procedures.
o Choosing the land for cultivation and suggesting the pesticides to be used as per the
EU MRL's.
o Overall hygiene monitoring inside the production facility and storage areas.
o Ensuring sound quality of all testing equipment including calibration.
o Ensuring GMP and SSOP for safe and quality manufacturing environment.
o Following ISO 9001:2000 and 5S proramme.

SRI LANKA PELWATTE SUGAR INDUSTRIES LTD

November 2005 - March 2006

Main Products: Sugar

o Supervising the raw materials, in-process materials and finished goods.
o Basic physio-chemical analysis of all incoming Sugar cane.
o Assuring and certifying Raw material quality parameters after harvesting in the field
level
o Calibration and maintenance of instruments and glassware handled.
o Studying the stability and mixability of the products.
o Studying the pilot trials and process implementation in the production.

Responsibility and Knowledge of Microbiology
➢ Responsibility

o Takes part in bacteriological examinations on a variety of samples, raw materials and finished goods.
o Performs microbiological examinations of food products, dairy products, soft
drinks, nonalcoholic beverages.
o Isolates and identifies microorganisms and maintains same in pure culture
condition.
o Adapts accepted procedures to special analyses as required.
o Prepares culture media and other reagents.
o Performs microbiological examinations of specimens submitted in conjunction with food poisoning investigations.
o Maintains records and prepares reports and correspondence related to work.
o Performs related work as assigned.

➢ Knowledge (Dairy Microbiology)

o Preparation of media (Milk agar, PDA, Tributyrin Agar, wort agar, TPC agar, etc).
o Preparation of Macconkey Broth, Brilliant Green Bile, Tryptone, K-vax Solution for
E-coli identification.
o Preparation of Peptone Solution, L(+) -Tartaric acid
o Identification of Lipolitic colony, Thermoduric, Thermophilic Bacteria colony, yeast and Mould, Total plate count, coliform, E-coli

Projects

Implement HACCP System in Orthodox Tea Manufacturing Industry

Main Products: Tea

oPrepared HACCP Manual and related documents.
oImplemented HACCP quality procedures.
oChoosing the land for cultivation and suggesting the pesticides to be used as per the EU MRL’s.
oOverall hygiene monitoring inside the production facility and storage areas.
oEnsuring sound quality of all testing equipment including calibration.
oEnsuring GMP and SSOP for safe and quality manufacturing environment.
oFollowing ISO 9001:2000 and 5S proramme.

Qualifications & Certifications

ISO 22000 FOOD SAFETY MANAGEMENT SYSTEMS (HACCP system)

Sri Lanka Standard Institution.

B.Sc. (Applied Science) Food Science and Technology (Special)

Faculty of Applied Sciences, Sabaragamuwa University of Sri Lanka

Sabaragamuwa University of Sri Lanka

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