exceeding brc expectations: addressing the human element of food safety

Copyright © 2016 Alchemy Systems

Exceeding BRC Expectations: Addressing the Human Element of Food SafetyJohn Kukoly, BRC Americas | Laura Dunn Nelson, Alchemy Systems

#alchemywebinarSeptember 8, 2016

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Welcome!

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Today’s Speakers

John KukolyBRC Global Standards, Americas Director

Laura Dunn NelsonVP of Business Development

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Agenda

• Key insights from the 4th annual Global Food Safety Training Survey

• BRC perspective on food safety training

• Common BRC audit results

• Closing the gap between training and food safety culture

• Q & A

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The Global Food Safety Training Survey

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Key Insights

• Commitment to Food Safety

• The Gap: Behavior Change

• Closing the Gap

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Global food safety training survey representation

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10%

9%

8%

8%

7%

7%7%

7%

6%

5%

4%

4%

4%3%

3% 2%2%1%1%Industry Sectors

Cereal and Bakery Packaging

Meats, Fish, Poultry Fruits & Vegetables

Beverages Dairy

Processed meats Processed produce

RTE's Ingredients/Flavors

Retail Sauces & Dressings

Sugar/Confections Fats & Oils

Sandwiches Catering & Hospitality

Feed Other

Warehouse/Distribution

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Geographic representation

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Mexico

Europe - non EU

Central/South America

Austrailia/Oceania

Canada

Asia

Africa/Middle East

UK

Europe - EU

USA

0% 5% 10% 15% 20% 25% 30% 35% 40% 45%

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Most important training goals

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Employee Retention

Skill Development

Positive Behavior Change

Safe Wholesome Product

Effective Employee Performance

Improve Food Safety Culture

0% 10% 20% 30% 40% 50% 60% 70% 80% 90%

#1

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o High turnover

o Lack of understanding

o Lack of time and resources

o Negative employee attitudes

? POLL

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What is your biggest challenge to developing a food safety culture?

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Biggest challenges to developing a strong food safety culture

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Lack of technology

Inability to measure culture

Culture is not priority

Lack of coordination

Lack of awareness

High turnover

Negative management attitudes

Multi-cultural workforce

Lack of effective communication

Negative employee attitudes

Lack of resources

0% 10% 20% 30% 40% 50% 60%

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Benefits experienced from effective employee training

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Lower turnover

Customer retention

Higher productivity

Fewer injuries

Higher morale

Reduction of customer complaints

Fewer food safety incidents

Improved food safety culture

Improved product quality

0% 10% 20% 30% 40% 50% 60% 70% 80% 90%

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OtherHorizon Scanning

GFSI Program OverviewProduct Sampling

Maintenance Staff ProgramFood Safety Culture

Validation/VerificationSupplier Audit/QA

Root Cause AnalysisRisk Assessments

Contractor/Visitor RequirementsFood Defense ProgramFood Quality Program

Corrective Action ProceduresInternal Auditing Program

Sanitation/CleaningAllergen ProgramTraceability/Recall

Food Safety ProgramPersonal Hygiene

GMP's

0 10 20 30 40 50 60 70 80 90 100

ManagerEmployees

Training topics

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Status Quo – Training Satisfaction

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Quality

Quantity

0% 20% 40% 60% 80% 100% 120%

Very satisfied Satisfied Somewhat satisfied Dissatisfied Very dissatisfied 14


GAPS

Learning

Doing

Despite our efforts we still have employees not following our food safety program on the plant floor.

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38%

62%

Yes

No

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Disparity in training time

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Management

Employees

0% 20% 40% 60% 80% 100% 120%

<4

4 to 8

9 to 15

16 to 20

21 to 30

31 to 35

>35

Hours Spent Training

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Temporary workers

• GMPS, Personal Hygiene,– Sanitation

– Cleaning

• Food Safety Culture,– Recalls

– Internal Auditing

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Temporary Staff

Equipment Suppliers

Services Suppliers

Raw Materials Suppliers

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

Supply Chain Training Requirements

Yes Yes, but not mandatoryNo No, but we plan to

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BRC perspective – food safety training

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Agenda

• How culture fits

• How FSMA ties in

• BRC audit results around training

• What’s new

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Organizational Culture

• Various support, and reinforcement mechanisms needed

• All levels fully supportive and involved

• Driven by culture, and drives culture

• Poor culture lessens uptake

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Relative to FSMA, and BRC

• Consider PCQI, and QI– Appropriately trained prior to work

(evidence?)– Includes everyone, temps and agency staff– Balance between training and supervision– CCP QI’s should have a competency

assessment– Training effectiveness and competency

assessment program– Records, and controls

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o Consistent application of training programs for temporary, contract, and agency employees

o Inadequate or incomplete documentation

o Unsatisfactory HACCP training

o Inadequate proficiency in food safety fundamentals

? POLL

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What is the #1 training non-conformity observed by BRC auditors?

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From BRC Audits…

• Individual training is generally well done

• Documentation gaps #1 training non-conformity

• Consistent application of programs for temps, agency and contractors second frequent non-conformity

• CCP training is generally well done, but ongoing assessment can be a challenge

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Leading Edge…

• Multiple training mechanisms, adjusted to fit purpose, and provide variety

• Understanding workforce differences in uptake, and behavior

• Cross linkages via automation and The Internet of Work

• Training depth – inclusion of the why rather than just what

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What’s new at BRC?

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How do you measure food safety culture?

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Strategies for Closing the Gaps

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Reasons for the training gaps?

1. Training lacks the ‘why’ component

2. Training effectiveness is not measured

3. Food safety is not a shared responsibility

4. Food safety training is not reinforced

5. Employee behaviors are not assessed on the plant floor to verify knowledge and application

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Sharing the ‘Why’

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Effective metrics – leading and lagging indicators

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Employee turnover

Cost per employee

Level of safety culture

Production output

Number of employees trained

Manufacturing defects

Product safety

Employee performance

Product quality

0% 10% 20% 30% 40% 50% 60% 70% 80%

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Who is responsible for training integration?

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64%11%

8%

8%

6% 2%1% Job function

QA/QC

Technical

HR

Other

Operations

External provider

Regulatory affairs

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Expanding our “training” definition

“If your goal is to produce long-term retention, and if

your goal is to produce behavior change, then what

you do after training is more important than what

you do during training,” - Dr. Art Kohn, Portland State University

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Rolling thunder – keeping training top of mind

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Other

Paycheck stuffer

Digital messaging

Newsletters

TV monitors

E-mail

Bulletin boards

Posters

Team meetings

Supervisor communications

0% 10% 20% 30% 40% 50% 60% 70%

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Rolling thunder - keeping safety top of mind…

Huddle Guide Poster

+ + +

Digital Signage Coach

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Impact of 24/7 awareness on retail food chain

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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 230.0%5.0%

10.0%15.0%20.0%25.0%30.0%35.0%40.0%45.0%50.0%55.0%60.0%65.0%70.0%75.0%80.0%85.0%90.0%95.0%

100.0%

Effects of Reducing the Communications Program in Weeks 9 thru 19

Store Audit Scores

Week Number


Employees are your best line of defense• Learning

– Consistency

• Communications– Drive retention through

reinforcement

• Performance– Coach and observe employee

behavior on the production floor

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Setting the stage for improvement

1. Insure training covers the ‘why’

2. Measure training effectiveness with leading indicators

3. Integrate food safety training responsibility across departments

4. Train supervisors to be effective coaches

5. Create ‘food safety campaigns’ to drive behaviors

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Date: Wednesday, September 28th | 12:00-1:00 pm CT

Speakers: Holly Mockus (Alchemy) & Kristin Kastrup (Alchemy)

Compliance in the area of recordkeeping and documentation continues to be a top challenge facing food industry professionals. It can be daunting to stay on top of FSIS, FSMA, and all the other changing requirements surrounding it. However, proper recordkeeping and documentation is critical because it can prevent a recall and protect you and your company against regulatory enforcement actions. Join two food industry experts with real-world experience from companies including ConAgra, Kellogg, and Sara Lee, who have faced these challenges first hand. They will point you to some of the regulations requiring documentation, explain why airtight records matter, and share best practices to ensure compliance.

Learning Objectives:• Discover why records matter• Understand the latest recordkeeping requirements• Determine the biggest risks of poor documentation• Learn industry best practices to ensure compliance

WebinarRecordkeeping & Documentation: Best Practices for Compliance


Q&A

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THANK YOUGlobal Food Safety Training Survey available at:

www.alchemysystems.com

New BRC resources available at: www.brcglobalstandards.com

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http://www.alchemysystems.com/

http://www.brcglobalstandards.com/