Compliance Success Stories

The client faced recurrent microbial contamination issues in their ultra-high-temperature (UHT) milk packaging lines, resulting in 4% product recalls and blocking vital supply contracts with premium national supermarkets.

• Conducted a exhaustive 3-day baseline Gap Analysis of the entire pasteurizing and cleanroom infrastructure.
• Identified latent biological hazards in the CIP (Clean-in-Place) piping joints and documented missing temperature logs.
• Established a rigorous Food Safety Culture framework and trained 140 shopfloor operators in critical hygienic zoning.
• Drafted a full set of FSSC 22000-compliant allergen, chemical validation, and trace-back manuals.

We completely overhauled their Hazard Analysis Critical Control Point (HACCP) matrix, replaced the faulty sanitary piping joints, and implemented a digital HACCP temperature tracking system. We upskilled their plant quality leads via certified Internal Auditor training.

The dairy plant successfully passed the external FSSC 22000 certification audit on the very first attempt with zero Major NCs. UHT product recall rates dropped from 4% to 0.05%, unlocking direct sales agreements with major retail chains.

High worker injury rates in the heavy metal forging press area resulted in state labor inspection penalties, heavy employee absenteeism, and poor production compliance.

• Performed an extensive HIRA (Hazard Identification & Risk Assessment) audit mapping 18 forging workstations.
• Redesigned the physical safety guards and implemented machine interlock standards as per ISO 45001.
• Created custom safety checklists in Marathi & Hindi to enable local laborers to log safety misses.
• Conducted behavioral health and safety drills and trained supervisors to manage emergency response procedures.

We established a robust ISO 45001:2018 Occupational Health & Safety Management System. TNS Consulting restructured the safety committee, created an internal safety auditor group, and executed root-cause analysis training for machine operators.

Zero severe industrial injuries recorded over 12 consecutive months. Employee absenteeism dropped by 35% due to enhanced workplace confidence. The factory earned the official ISO 45001 and ISO 14001 integrated safety certification.

The laboratory needed NABL (ISO/IEC 17025) accreditation to qualify for profitable environmental testing tenders from state government agencies, but struggled with calculating calibration uncertainty budgets and quality assurance control charts.

• Conducted deep mentoring on chemical testing uncertainty calculations, establishing robust standard deviation metrics.
• Reviewed and updated the calibration certificates of over 120 gas chromatographs and analytical instruments.
• Prepared full Quality Manuals matching the ISO/IEC 17025:2017 regulatory framework.
• Simulated a comprehensive mock NABL audit to stress-test staff competence and laboratory data integrity.

We trained and certified 15 laboratory scientists in uncertainty of measurement and internal auditing. We designed their official calibration traceability matrix and structured laboratory sample control protocols.

The facility cleared the physical NABL audit with zero major findings, securing the ISO/IEC 17025:2017 accreditation within 6 months. This enabled them to immediately bid for and win 4 state environmental monitoring projects.