Oka Foods Việt Nam | Quality management

QUALITY MONITORING AND CONTROLLING

01 Planning

Based on new needs that we found while looking for customer’s concern, interest and lifestyle, we’ve developing product by repeating meeting and prototype many times.

We aim to develop useful products for cooking places and delicious meals for all eaters as well as increasing our raw material procurement and products development.

02 Purchasement

Raw materials are purchased through the Oka Foods Sourcing Network which spreading around the world. We’ve been worked to ensure the stable supply by establishing a long term and mutually beneficial relationship with producers. Because of smell’s issue of raw seafood material after fishing,

we’ve to pay attention to management of raw material closely such as temperature. In addition, by commercializing high quality and affordable fish species but not yet known in Japan, we are making efforts to delight not only consumers but also local raw material producers.

03 Processing

Raw materials usually differ in size and shape. Such raw materials will be cut into same weights and shapes by skilled workers. Remaining fish bones can be a problem, especially serving old person. In order to remove all remaining bones, we conduct multiple inspections

using X-ray system until completion. In addition, we’re carrying out many activities to improve production environment, such as environmental improvement of factories and QC activities.

04 Distribution and sales

Products produced at overseas factories are stored in freezer storehouse in Japan and automatically delivered

according to purchase order, then and transported nationwide. It is often delivered to customer at the market.

05 Cooking

From the request “insufficient labor cost and take many time” at the cooking places or “I want a delicious fillet that doesn’t smell”, it’s possible to cook directly from freezing to save time but plump weight, soft and odorless dish was born.

Since the thickness of fillets almost same size, so over cooking rarely occur, along with many ideas have been implemented to make cooker and eater happy.

OKA FOODS QUALITY MANAGEMENT SYSTEM

Policy of Quality

We will stably provide customers with good products that do not have “baratsuki,” from raw materials to where they’d been cooked as well as meet “reliable”, “safety” and “low cost” needs.

Safety and Security Initiatives(1. Assurance; 2. Safety; 3. Cost)

Oka Foods is a fabless manufacturer (it does not have a factory at its own company), but since its establishment in 1975, we have been working hard on safety and security. From the beginning of the 1950’s, he taught hygiene management to a consignee’s fish processing plant centering on Sanriku, and at that time carried out wearing of a rare white coat, mask and hat and inspection before entering the room.

We will put emphasis on factory hygiene management education at major factories in Japan and overseas. Our company welcomes Ms. Nakayama as an adviser for providing practical hygiene management guidance and study sessions for all workers. It is In addition, with the increase in overseas production today, it is necessary for plant workers to understand “Why do we need fish for bones and what kind of problems will occur if bones are left?”. We also offer “Japanese training”.

Management system from purchasing raw materials to commercialization

1 - Raw material management

At the time of raw material procurement, the purchase is carried out after direct inspection at a local site by Oka Foods’ experienced purchaser or the “fish professional” who received the request. At that time, only the raw materials have the certificate of origin can be obtained are purchased. So, all of our products have traceability.

2 - Factory management

With respect to factories which we intend to consign processing, our staff and external experts have to visit in advance and contract only to the factories that meet our quality policy.

In addition, we place top priority on the development of managers including plant managers and production managers. We believe that it is necessary for these layers not only to do what they have been told, but also to be able to think voluntarily and make continual improvement. So, our staff and outside experts visit the site regularly to focus on improving management technology and mindset. We also organize regular study sessions for the site workers. The theme of training session is not only to raise awareness of quality and improve skills but also to know how Oka Foods products are cooked and eaten. This will enable us to understand the meaning of our daily work.

Furthermore, we are actively working not only on workplaces but also on living environment, such as adjustment of illumination on the workbench in the factory, improvement of meals, improvement of employee dormitories and environmental beautification.

3 - Product management

With manufactured products at overseas factories, inspection are conducted in our QA room upon receipt and after processing, and only safe and secure products that meet the standards defined by the Japanese law are shipped.

New products etc. are inspected for initial flow control before shipment from the factory and at the time of product arrival, and it is confirmed whether there is any variation in quality.

4 - Storage and logistics management

From storage to delivery products, we collectively entrust them to Hutech Norin Co., Ltd., a specialized refrigeration distribution company, to manage storage temperature and shelf life of inventory, shipping history, temperature control and recording during delivery, etc

For the realization of "reliable and safe to the place you use"

In order to use our products "reliability and security", we hold study sessions for chef cooks and dietitians who are actually using it and all the dealers who handle it. . In addition, we issue and distribute brochures with useful knowledge and examples, such as "Funny dictionary to enjoy eating fish" and " Q & A of fish ecology". Besides, we have actively provided opportunities to explain product specifications, how to use them, and fish characteristics at exhibitions, seminars and websites.

Inspection system for safety and security

www.okafoods.jp/safety/test.html

This is an example of the flow of inspection system until products manufactured are imported into Japan. At the production site of Oka Foods products, we carefully inspect raw materials, plants, products, and everything for safety and security of product quality.

1. Raw materials used

We use only safe and secure raw materials that can be traced.

2. Raw material inspection

Imported raw materials are subject to voluntary inspections and public institution (CIQ) inspections with each inspection certificate.

3. Product processing

In the factory, we will carry out defense inspection and water quality inspection.

4. Product inspection

Products are sampled for each lot and microbiology testing is performed.

5. Product storage

Store in a freezer with thorough temperature control.

6. Pre-shipment inspection

Prior to shipment, heavy metal inspections will be conducted at public organization (CIQ).

7. Product storage

The container ensures thorough temperature control and regularly checks that the temperature is properly maintained with an automatic thermometer.

8. Ship to Japan

Products that passed the inspection of National Commodity Inspection Bureau are imported into Japan.

9. Import examination

When arriving in Japan, the Ministry of Health, Labor and Welfare will conduct a review under the Food Sanitation Law by the Ministry of Health, Labor and Welfare Quarantine Station.

10. Customs duties

Examination required

11. Public inspection

- Monitoring inspection by Ministry of Health, Labor and Welfare & other government agencies.

12. Frozen storage and shipping

It is stored and delivered under thorough temperature control.

CONTROL OF PRODUCTION SITE MANAGEMENT

We are continuously working to improve the quality awareness and staff productivity for better product

Safety and Security Initiatives

Since its founding, Oka Foods has set its motto as a “factory without manufacture” as its motto, and even with its own brand products, all production is outsourced to domestic and overseas partner factories. However, Oka Foods does more than just receive the product from the outsourced factory.

By centralizing management from the flow of raw materials to products and taking leadership in production and quality control, we aim to produce “reliable, safe and low cost” products with “small quantity, high variety and short delivery time”.

https://okafoods.jp/safety/production.html

Manage “not” Monitor

First and foremost, we place top priority on the education and development of field managers, including plant managers of cooperating plants. We are trying to improve at overall level with the concept of putting on-site ability and management ability from trained personnel to on-site leaders and workers. So that, along with raw materials procurement, production management, quality control, product development, marketing, sales, etc. representatives and executives frequently also visit to conduct meetings and improvement activities. We are working with the outsourcing staff to confirm and improve the situation on the site and improve the management technology. Absolutely it takes time, effort and cost, but it is intended to grow together with the factory in such a way to ensure our business strength and management ability.

Regular mutual visits

Currently, there are various needs for fish but since the time of the founding 40 years ago of Oka Foods, the added value products and required quality have changed significantly. In comparison of the time of establishment, there were many products for lunch likes box lunch and school lunch and also the focus on fillets and fillets with bones. Demand for baked products is increasing.

We visit the production site regularly and tell people there to understand, "Who will produce and consume what products are produced on the site?" By doing this, we are working to improve the quality awareness and work levels of people in the field.

On the other hand, we also have Japanese and Vietnamese partner factories visit Japan regularly. By touching the food and lifestyle culture of Japan and seeing, feeling with their own eyes how they actually consume the products they have made, they have a concrete grasp of the image. The purpose is to further improve on-site capabilities by having the lessons learned in Japan used in on-site production and improvement activities.

MORE INFORMATION

History and development of Oka Foods Company

Branches and partners of Oka Foods Company

About Oka Foods

All of the factories in China and Vietnam have obtained ISO 22000, HACCP certification and other under the law. We strive to produce better products by management and to deliver safety and security to customers according to the standards established by the world.