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Implementing SQF Training for Food Safety SuccessFood Safety Success
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2000 Powell St., Suite 600, Emeryville, CA 94608 || (510) 452-8000 || www.scsglobalservices.com
“ The only thing worse than training good employees and losing them,
“good employees and losing them, is not training your employees and keeping them”and keeping them.
—Zig Ziglarg g
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Reasons for Training …same as Food Safety
Regulations and retail buyer requirements
Health: Food borne illness + “at risk” populationsHealth: Food borne illness + at risk populations
The micro world: increased “virulence” and adaptation & better detectionadaptation & better detection
Global food supply & technology/transportation
Risk of Liability
Media – avoid Media avoid negative press
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Top four food safety problemsIndependent experts hired by the FDA identified these issues:
1. "deficient employee training,"1. deficient employee training,
2. “contamination of raw materials,"
3. "poor plant and equipment sanitation,"
4 "poor plant design and construction”4. poor plant design and construction .
Preventive Control = Training ‐ Ongoing and targeted training on issues ranging from allergen control cleaning and sanitation proceduresissues ranging from allergen control, cleaning and sanitation procedures, incoming ingredient receipt protocol, and monitoring for employees, management, as well as suppliers.
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Current Good Manufacturing Practices (cGMPs) Creation & Document
Control of SOP/SSOPs Training & Education of
Revisions to CGMPs ‐2 types : one for HARPC (21 CFR pt 117) and one for Produce
Personnel Personnel Practices –
hygiene, product handlingM i t f G d
Rule (21 CFR pt 112)
Maintenance of Grounds Pest Control Safe Water Supply &
Plumbing
based on FDA Regulation 21 CFR110 10Plumbing
Cold Storage Monitoring Transport – product
shipping and distribution
21 CFR110.10
shipping and distribution Microbial Testing Pre‐inspection procedures –
cleaning & sanitation Food GMP Modernization Working Group Report
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FSMA rules:(Food Safety Modernization Act)
The CGMP and Hazard Analysis and Risk-Based Preventative Controls for Human Food Rule - FDA isPreventative Controls for Human Food Rule - FDA is requesting comment on whether it should mandate training for employees and supervisors, including a requirement for records that document training.records that document training.
The Produce rule would require training for farm personnel who handle the produce or food-contact surfaces, and for supervisors.
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Training & need to revise CGMPs
Comments ~ “Food safety specifications
"...training is essential to making all the other control elements
y prequired from the top down through the supply chain are far more stringent and
effective.”are far more stringent and effective than regulatory requirements.”
Food GMP Modernization Working Group Report
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GFSI International Food Safety Standards
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Global Food Safety Training 2013
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What can you expect from employees (who do t i l i t ti /t i i )?not receive clear instructions/training)?Imagine the Result of Poor (or no) Instructions
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Awareness – understand what needs to be done
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SQF Training Center – what is offered
Course: 2‐day Implementing SQF Systems Courses – either 1000/Pre‐farm gate (GAP) or 2000/Post farm‐gate (GMP)
For whom? Employees who are responsible for designing, implementing and maintaining the Code are encouraged to participate in a training course.participate in a training course.
Course Outline• Introduction to SQF and Implementing SQF Training• Introduction to SQF and Implementing SQF Training • Preparing for SQF Certification• SQF Certification Process• Implementing an SQF SystemImplementing an SQF System• SQF System Elements (Module 2)• GAPs and Pre-Farm Gate (Module 7 and its derivatives)• Or GMPs and Post-Farm Gate (Module 11 and its derivatives)
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( )
HACCP Prerequisite 2‐day training HACCP training — 2‐day (or equivalent) + exam for Practitioner and other employees involved; Must have an understanding of HACCP principles and process and their roleHACCP principles and process, and their role.
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Training Goals: Implementing the SQF course
Promote an understanding of the SQF Code.
Create a knowledge base to facilitate the successful Create a knowledge base to facilitate the successful implementation of an SQF System.
Show how a HACCP‐based approach manages food safety and Show how a HACCP‐based approach manages food safety and quality hazards in an operation.
Discuss new regulatory and safety requirements. Meets SQF’s training requirement.
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Training & Educational Options
Public courses
In‐house courses
Public / in‐housePublic / in house
Online SQFI
Consultants
SQF Resources online – Code, updates, checklists, guidance documents, food sectors, audit duration…
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SQF Trainer and Training Center requirements
SQF trainers • 2‐ 4 years experience developing, managing and maintaining a food safety programmaintaining a food safety program• at least one (1) food sector category or be an SQF registered consultant/auditor3 i i i h i l f d f / li• 3 years experience training technical food safety / quality
adult training courses (20 training days)
( ) l l f h Training Center (TC) gets Evaluations upon completion of the course.
d d f f d TC provides Binders, Certificate of Attendance. For an SQF Certificate – trainee must pass exam with 75+%. 3x to retake.
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2.9.1 SQF Code Training Requirements ‐ audited Appropriate training shall be provided for personnel
‐ job specific‐ needs analysis‐ needs analysis
Training may be completed on the job by qualified technical staff or externally by recognized institutionsstaff or externally by recognized institutions.
Instructions shall be available ‐ specific
Document and implement
Language/literacy g g / y
Refresher Training
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Learning Design – appropriate training A Learning Design is a planned experience (e.g., a Strategy involving a number of instructional methods, activities and resources) that facilitates desired learning outcomes for aresources) that facilitates desired learning outcomes for a group of students.
When we systematically (and perhaps creatively) plan our When we systematically (and perhaps creatively) plan our lessons for the students we teach, this is a learning design.
What is important however is that the design is most What is important, however, is that the design is most effective and efficient for facilitating the desired learning for that particular group of students.
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Preventative Maintenance ‐ Refresher Training
Schedule regular gpreventive maintenance (updates to Code, legislation risklegislation, risk level/corrective actions?)
In house or vendor In‐house or vendor
Keep certificates available for auditorsavailable for auditors
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Global Food Safety Training 2013
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Other related benefits of Trainingg…similar to benefits of HACCP +
D i d k d il Drive down rework and spoilage costs. Reduce liability related to food safety. Improve consistency in product safety & quality. Compliance with Regulatory & Retailers = Sales
Keep on top of it!Keep on top of it!
Training, like HACCP, should be Preventive!
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Provide classroom training O th J b t i i b lifi d lor On‐the‐Job training by qualified personnel.
Good trainers!Stories/examples,experience, d ieducationup‐to‐date
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Leveraging Your SQF Systemeveraging Your SQF System
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Effectiveness
2.9.7. Training Skills Register
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Alignment = Buying In
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Food Safety is Educational
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Food Safety and Quality
Who is responsible?
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Everybody is Responsible!!
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Who Needs To Be Trained?
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Employee Training Program
3 Levels Senior Middle
Management/ QA
All Employees /3 Levels Mgmt QA
Professionals/ Workers
SQF ElementsBCP, Management Commitment &
GMPs/GAP HACCP SOP/SSOPs SQF Elements Commitment &
ReviewHACCP training
/WINs
Documentation Training Topics covered, trainer name andDocumentation Records trainer, name and
signature of attendees
Refresher Training Annual /seasonal Refresher Training (as needed)
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Definition of the SQF System
“A RISK management and PREVENTATIVEsystem that includes a Food Safety plan and Quality Plan at level 3 implemented and operated by a supplier to ASSURE food safety and quality (Level 3).”
SQF Code Edition 7. p. 152
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Management & Supervisors
Food Safety Element Responsibility2.2.1 Document Control
2.3.1. Product Development
2.2.1. QA Manager / SQFP
2.3.1. R&D Manager
2.4.5 Incoming Goods
2 5 7 I l A di
2.4.5. Purchasing Manager
2 5 7 QA M / SQFP2.5.7 Internal Audits 2.5.7. QA Manager / SQFP
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Management & SupervisorsFood Safety Program2.6.1. Withdrawal & Recall
Responsibility2.6.1. CEO & Crisis Team
2.8.2. Allergen Program 2.8.2. Warehouse, Production, and Sanitation Managers
11.2.9. Premises & Equipment Maintenance
11.2.9. Maintenance Manager
11.2.13. Cleaning & Sanitation
11.2.13. Sanitation Manager
11.3. Personal Hygiene 11.3. All Managers
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Food Safety d QA P f i land QA Professionals
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QA Manager / SQFP
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All Employees ‐ Admin & Floor
HACCP Team training
Packaging Operator ‐ Net Weight Control, Codification, Labeling, CCP Metal Detector & g,Kill Step
Operators ‐ CP Monitoring food p gSafety plan. Magnets, Screens, Sifters
QC Techs ‐ Sampling & Analysis, Raw Materials, Calibration Scales & Thermometers
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Scales & Thermometers
All Employees ‐ Admin & Floor, continued
Maintenance Tech —GMPs for Maintenance Personnel, Clean‐up procedure
Sanitation Operator — SSOPs, MSDS, Handling Chemicals, Verification of correct concentration of Detergents and Sanitizers
Customer Service — Complaint Management
All E l I d P M (IPM) All Employees —Integrated Pest Management (IPM)
Receptionist — Visitors Policy
Forklift Operator — Loading & Unloading procedures, Allergen Program, Storage GMPs, Stock Rotation
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Language / Literacy 2.9.5.1
Training materials and the delivery of training shall be provided in language understood by staff – note commonprovided in language understood by staff note common languages + literacy
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Maintenance: 2.9.6. Refresher Training Identify and Implement refresher training based on needs of organization.
Depends on program, SQF System review, Seasonal Product or not, Turnover, etc.
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Case Studies
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Case Study: Bakery
600 Employees
80% Spanish speaking 80% Spanish‐speaking
10% Chinese‐speaking and other languages
10% English‐speaking
Frozen baked breads bagels donuts danish Frozen baked breads, bagels, donuts, danish
4 lines
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Bakery, continued
SQF Certificate was suspended
Conducted gap analysis to find root causes Conducted gap analysis to find root causes
Findings: Employees did not know about SQF
Conducted SQF Overview training for all employees (WIFM & WSIC)
Trained Managers & Supervisors on SQF PRPs
Trained relevant employees on specific tasks Trained relevant employees on specific tasks
Company got certificate back in 3 months
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Quality Control (QC) Model
Fact: Low skilled workers
Inspectors backing up workers Inspectors backing up workers
Inspectors Accountable for Food Safety & QA
Worker focus is productivity
Creates friction Creates friction
QC model doesn’t focus on waste management
Management outside of QA is not accountable for Food Safety & QA
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Quality Management Systems (QMS) Model
Sr. Management Committed to Food Safety
All Management Accountable for Food Safety & QA All Management Accountable for Food Safety & QA
QA/SQFP plays a control & support role
Worker role is productivity with food safety & QA
SQF Training programs must be in place & effective to train SQF Training programs must be in place & effective to train lower skilled workers
QMS model focuses on CI and waste reduction QMS model focuses on CI and waste reduction
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Management and Supervisors
System Design Tip (QMS vs. QC)
Designate Food Safety and Quality Responsibilities Designate Food Safety and Quality Responsibilities according to function of each Manager in the Org. Chart
Trickle down those responsibilities to the team according Trickle down those responsibilities to the team according to the Org. Chart
Develop Job Descriptions accordingly Develop Job Descriptions accordingly
Build the capacity of your team following SQF Training Program RequirementsProgram Requirements
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QC vs. QMS
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Case Study: Snack Manufacturer
Coated Apple and Snack Company
85 Employees 85 Employees
90% low skilled Spanish‐speaking workers
Chocolate & Caramel Coated Apples, Popcorn & Tortilla Chips
2 lines
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Snack Manufacturer, continued Company used QC Model
When Implementing SQF — adopted QMS Model p g p
Re‐assigned Food Safety & QA responsibilities & Accountabilities
Delivered SQF Training to entire organization
Savings on 10% of the labor — 85 Employees
Total Savings $183k / Year ($915k / 5 years)
Company got SQF Level 2 Certification with 98% Score
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Your Certification Success – Audit assesses each facility by interview and examination of records.
Evidence may include: • Have you done a Training needs analysis? • Is it based on job descriptions? • Does it includes all shifts and relief?includes all shifts and relief?
Poor training results could result in a finding for non‐conformance and a delay in certification while timeconformance and a delay in certification, while time‐consuming corrective actions are taken.
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Benefits of Comprehensive SQF Training
Everybody embraces Food Safety & QA
Waste reduction (Raw Materials Product Labor) Waste reduction (Raw Materials, Product, Labor)
Increases Productivity (QC vs. QMS)
Increases Employee Morale / Reduces Turn‐over
Reduces the number of Non Conformances in Audits Reduces the number of Non Conformances in Audits
Reduces Risk associated with Food Safety Scares
Retains Customers = Stay in Business
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Summary – Training has same goals as the Food Safety / HACCP program in your companyFood Safety / HACCP program in your company
D t i t i t T i i M th d( ) Determine most appropriate Training Method(s)
Determine most likely areas for hazard issues
Build corrective actions for the potential errors
Build in goals of performance with the data
Use testing/validation as a constructive tool
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Think of Training as the fuel needed to keep moving forward – on track, safely getting your product where you want it!
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Questions?
SCS Food & Agriculture Team: Diane Dulmage, Training Manager, [email protected] Diane Dulmage, Training Manager, [email protected] Oscar Camacho, SQF Trainer, [email protected] Chip Wood, Dir Business Development, [email protected] Heena Patel, Food Safety Auditing Dir, [email protected] Carole Langston, Account Manager, [email protected] Wil Sumner, Food & Ag Testing Dir, [email protected] many more!
510-452-8000 || www.scsglobalservices.com/food-and-agriculture
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