The Problem: Quality as an Assumption, Not a System

Hey Reader,

In most protein operations, quality is still treated as an assumption, something that should naturally happen if everyone "does their job." When something goes wrong, the default response is to ask, “Where was QA?” But that mindset is flawed. Quality isn’t the result of inspection. It is the outcome of a system. And when that system is out of control, blaming QA doesn’t fix it, it hides the real issue.

This legacy mindset is understandable. Proteins are naturally variable. Operators are under intense pressure to minimize costs and maximize yields. But chasing efficiency at the expense of quality creates a shaky foundation. If we want consistent, profitable operations, we need to build quality in, not inspect it out.

The Shift: Production Owns Quality, QA Verifies the System

To move forward, we need a new operating model:

• Production owns quality.
• QA verifies system control.

This is not just semantics. It is a fundamental shift in how accountability is structured.

Here’s what that looks like in practice:

• QA conducts both in-process and finished product audits to verify whether the system is in control, not just whether the product meets spec.
• When something is out of spec, QA should lead a root cause analysis with Production, not for them.
• Real-time data is critical so teams can catch problems as they emerge, not after the product is boxed and labeled.

This model doesn’t reduce QA’s role, it elevates it. QA becomes a strategic partner focused on system stability, not just post-process inspection.

Case Study: Work Cells and Embedded QA

While at Kroger, we worked with a supplier to bring this concept to life. Instead of inspecting at the end of the line, we restructured QA around work cells. The entire process was divided into manageable cells, and QA personnel were embedded at the end of each cell. This did three things:

1. Shifted from end-of-line inspection to in-line coaching. QA wasn’t just catching defects, they were preventing them.
2. Multiplied visibility. We saw significantly more product without slowing down the line.
3. Empowered QA. They were given E-stop authority if the process went out of control, driving accountability and urgency.

The result: a more consistent product, fewer surprises, and a frontline team that bought into quality improvement because they could see real-time changes and coaching, not after-the-fact reprimands.

Building Quality into the Process

Here’s how to put this into action, even without a major restructure:

• Redefine roles: Make it explicit that Production is responsible for producing to spec. QA verifies system performance.
• Use in-process audits, not just finished goods audits. They reveal whether the system is working, not just the end product.
• Build feedback loops: QA findings should be immediately reviewed with operators and supervisors, with clear next steps.
• Track control metrics in real time. Focus on spec-critical indicators like product and fat thickness or leaker rates. These metrics tell you whether the process is stable and whether you’re hitting the customer-defined target every time.
• Give QA stop authority. It is a bold move, but one that signals quality is non-negotiable.

Bottom Line

Quality is not a checkpoint. It is a consequence. If you want consistent quality, you need a system that consistently delivers it. That system starts with Production, and it is supported, not policed, by QA.

When QA becomes a strategic process partner rather than an end-of-line gatekeeper, quality improves, costs drop, and your operation gets a lot less reactive.

FreshOps in the Field

If you enjoyed our recent issue on The Necessity & Fallacy of Planning, check out my latest appearance on the MeatingPod podcast by MeatingPlace.

In Episode 237: “How to Play the Long CapEx Game,” we expand on that topic and talk about how long-range capital planning must move beyond the immediate problem solving. The conversation covers a different framework to evaluate CapEx purchases, the critical groups to involve in CapEx conversations, and why you should have a consistent rhythm to discuss your future based assumptions.

​Listen now​

It is a practical listen for protein leaders who want to drive lasting improvements in complex environments.

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FreshOps | Practical Insights for Fresh Food Operations

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P.S. IFFA Recap is available!

This year’s IFFA show in Frankfurt was packed with future-shaping insights from automation designed to address labor gaps to packaging trends that haven’t even reached the U.S. market yet.

I put together a focused recap specifically for protein producers and retailers. It’s designed to help you anticipate what’s coming and begin realigning your strategy now, before the next wave hits.

Three ways to access it:

• Single Chapter – $245
• Full Report – $995
• Full Report + Consultation – $1,495

Learn more and purchase here: https://buildingblock.solutions/iffa-recap-report​

P.P.S. Want to know 5 Cost Saving Upgrades from IFFA?

Not sure if the Recap report is for you? This FREE 2 page guide shares some of our insights that could provide immediate value to your operation.
​Get the free pdf guide here​
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