Staff training is a recognised major part of addressing product manufacturing safety risks – and the food sector is no exception. An appropriate level of investment in training should deliver clear bottom line benefits – whereas under-spending to save money will have exactly the opposite result.
However, a ‘Best Manufacturing Practices Survey’ report found that companies ranked training as the least effective food safety measure. It is essential to understand the reasons underlying this perception – and identify ways in which trainings effectiveness can be improved.
The three broad food hazard categories provide a road map for training.
Microbiological hazards:
The area generating the highest proportion of food related illnesses – it includes pathogenic bacteria, viruses and parasites. Inadequate training may result in improper or inefficient hygienic practises, biofilms, ineffective use of cleaning agents/disinfectants, reactive instead of routine maintenance and even post-processing contamination.
Chemical hazards:
Hazards associated with chemical use vary widely. Inadequate training can result in improper use and management of chemicals and the processes associated with them. This can lead to contamination through cleaner/sanitizer residue, corrosion, raw material contaminated with pesticides, spillages of pesticides, in-line cross-contamination with allergens and even the incorrect labelling of chemicals.
Physical hazards:
Improper procedures can result in foreign objects finding their way into the finished product. Different types of foreign substances will manifest themselves at different stages of the production process. The raw material stage would typically be contaminated by primary substances – soil, metal, wood, organic matter. During the production phase, inefficiently maintained equipment could result in processed materials - plastics, metal, wood etc. – turning up in the final product. Lastly, the storage phase will result in different types of material getting into the final product. The impact of each is significant and highlights how training linked to the specific process is required to minimise hazards.
The increased use of GMP and HACCP has significantly reduced the risk of contamination. But how you make sure that these standards are understood and followed there are a range of ‘softer’ issues which need to be identified. These softer considerations are equally important and must be factored into your training to ensure it has the required result.
Language Barriers:
Enhance communicative effectiveness through using the recipient’s first language, visual aids and interactive training. Own language use and visual aids are essential to breaking down language barriers. Experiential training through interaction with supporting training materials (like GloGerm Gel, Powder, detection Gel) reinforces understanding and creates confidence. Furthermore, training should be conducted routinely through on-going training.
Training Frequency
An initial intensive course (1 or 2 days) followed by regular reinforcement sessions of 20 minutes per week is seen as sufficient for most companies. A short course held at a weekly meeting or even updates on industry related news can enhance understanding over a period of time
Commitment issues:
In a tough economic environment, finding the budget to maintain and expand on training activity is a challenge. Available funds are diverted to critical items. If training is withheld, this will lead to some loss of knowledge and procedural breakdown amongst staff. If training Is regarded as a low impact safety technique, it’s likely that training will be effected
Generic Training
Each product and factory layout is unique and training must therefore be tailored to suit the environment that staff deal with. Niche area’s should be identified and the appropriate means of keeping these clean should be established and then appropriate training – and as importantly, tools – provided.
Operating Procedures
Plant renovations can have an effect on how staff operate during the production process. As a consequence, SOP’s need to be reviewed to ensure they still apply in the current workplace configuration.
Targeted training
Other impediments to effective training might include training the wrong people or not training enough people
The above list highlights some of the significant areas, but can be extended. What is clear is that training can be used to address every aspect of the production process and play a part in reducing safety risks with every hazard food manufacturer’s face.
For training to take its place as a primary food safety technique, the way it’s role in food safety is perceived needs to be addressed. The bad news there is no quick solution – the good news is that training does have a positive return on investment. A study conducted in Belgium in 2006 and reconfirmed in 2009 showed that increased training had a positive impact on productivity in the food industry. Effective training reduces costs resulting from equipment brakeage, consumables wastage and products spoilage. Further studies showed the dismissal and quit rates are lower in companies – which reduces labour costs overall.
Well trained workers are less likely to quit. High levels of firm-specific training results in acquired skills which are not necessarily applicable to other organisations. Departing staff face earning lower wages at companies where their skills are not entirely appropriate. Alternatively, companies are less likely to fire trained workers due to improved performance and the impact of skills loss. A stable and effective workforce is more likely to be a happier one. The consequent improvement in working relations will have an effect on the organisation as a whole – the improved working atmosphere will result in further productivity gains associated with a happy working environment.
Improved use of consumables, materials and equipment will result in lower operating costs. Likewise, improved SOP’s in every area of the production process can generate meaningful cost savings. Proper training is vital to ensure that cost efficiency initiatives are properly implemented and actually achieve the desired benefit. Properly conducted, it should rightfully be seen as the cornerstone of effective safety management.
