Exceeding BRC Expectations: Addressing the Human Element of Food Safety
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The 2016 Global Food Safety Training Survey revealed an astounding 62% of food companies say that not all of their employees are following the right food safety protocols on the floor. However, 75% of those food companies agreed that employees would be more productive if their food safety program was consistently applied. Have you ever wondered if your training methods are driving the right food safety behaviors and results? Once upon a time, the food industry’s approach to food safety focused on inspection results, facility design, microbiology, and illness outbreaks. The future of food safety, as outlined by BRC 7, now includes and emphasizes people and their behavior.
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Exceeding BRC Expectations: Addressing the Human Element of Food Safety
- 1. Copyright © 2016 Alchemy Systems Exceeding BRC Expectations: Addressing the Human Element of Food Safety John Kukoly, BRC Americas | Laura Dunn Nelson, Alchemy Systems #alchemywebinar September 8, 2016
- 2. Copyright © 2016 Alchemy Systems • Audio Options: – Choose “Mic & Speakers” to use computer speakers – Choose “Telephone” to dial in using info provided • All lines are in listen-only mode • Please post your questions at any time • A link to the recording will be emailed shortly after the event Welcome! #alchemywebinar 2
- 3. Copyright © 2016 Alchemy Systems Today’s Speakers John Kukoly BRC Global Standards, Americas Director Laura Dunn Nelson VP of Business Development #alchemywebinar 3
- 4. Copyright © 2016 Alchemy Systems 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 #alchemywebinar 4
- 5. Copyright © 2016 Alchemy Systems The Global Food Safety Training Survey 5
- 6. Copyright © 2016 Alchemy Systems Key Insights • Commitment to Food Safety • The Gap: Behavior Change • Closing the Gap #alchemywebinar 6
- 7. Copyright © 2016 Alchemy Systems Global food safety training survey representation #alchemywebinar 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 7
- 8. Copyright © 2016 Alchemy Systems Geographic representation #alchemywebinar 0% 5% 10% 15% 20% 25% 30% 35% 40% 45% Mexico Europe - non EU Central/South America Austrailia/Oceania Canada Asia Africa/Middle East UK Europe - EU USA 8
- 9. Copyright © 2016 Alchemy Systems Most important training goals #alchemywebinar 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% Employee Retention Skill Development Positive Behavior Change Safe Wholesome Product Effective Employee Performance Improve Food Safety Culture 9
- 10. Copyright © 2016 Alchemy Systems o High turnover o Lack of understanding o Lack of time and resources o Negative employee attitudes ? POLL #alchemywebinar What is your biggest challenge to developing a food safety culture? 10
- 11. Copyright © 2016 Alchemy Systems Biggest challenges to developing a strong food safety culture #alchemywebinar 0% 10% 20% 30% 40% 50% 60% 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 11
- 12. Copyright © 2016 Alchemy Systems Benefits experienced from effective employee training #alchemywebinar 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 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 12
- 13. Copyright © 2016 Alchemy Systems 0 20 40 60 80 100 Other Horizon Scanning GFSI Program Overview Product Sampling Maintenance Staff Program Food Safety Culture Validation/Verification Supplier Audit/QA Root Cause Analysis Risk Assessments Contractor/Visitor Requirements Food Defense Program Food Quality Program Corrective Action Procedures Internal Auditing Program Sanitation/Cleaning Allergen Program Traceability/Recall Food Safety Program Personal Hygiene GMP's Manager Employees Training topics 13
- 14. Copyright © 2016 Alchemy Systems Status Quo – Training Satisfaction #alchemywebinar 0% 20% 40% 60% 80% 100% 120% Quality Quantity Very satisfied Satisfied Somewhat satisfied Dissatisfied Very dissatisfied 14
- 15. Copyright © 2016 Alchemy Systems GAPS Learning Doing Despite our efforts we still have employees not following our food safety program on the plant floor. #alchemywebinar 38% 62% Yes No 15
- 16. Copyright © 2016 Alchemy Systems Disparity in training time #alchemywebinar 0% 20% 40% 60% 80% 100% 120% Management Employees <4 4 to 8 9 to 15 16 to 20 21 to 30 31 to 35 >35 Hours Spent Training 16
- 17. Copyright © 2016 Alchemy Systems Temporary workers • GMPS, Personal Hygiene, – Sanitation – Cleaning • Food Safety Culture, – Recalls – Internal Auditing #alchemywebinar 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% Temporary Staff Equipment Suppliers Services Suppliers Raw Materials Suppliers Supply Chain Training Requirements Yes Yes, but not mandatory No No, but we plan to 17
- 18. Copyright © 2016 Alchemy Systems BRC perspective – food safety training #alchemywebinar 18
- 19. Copyright © 2016 Alchemy Systems Agenda • How culture fits • How FSMA ties in • BRC audit results around training • What’s new #alchemywebinar 19
- 20. Copyright © 2016 Alchemy Systems Organizational Culture • Various support, and reinforcement mechanisms needed • All levels fully supportive and involved • Driven by culture, and drives culture • Poor culture lessens uptake #alchemywebinar 20
- 21. Copyright © 2016 Alchemy Systems 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 #alchemywebinar 21
- 22. Copyright © 2016 Alchemy Systems 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 #alchemywebinar What is the #1 training non-conformity observed by BRC auditors? 22
- 23. Copyright © 2016 Alchemy Systems 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 #alchemywebinar 23
- 24. Copyright © 2016 Alchemy Systems 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 #alchemywebinar 24
- 25. Copyright © 2016 Alchemy Systems What’s new at BRC? #alchemywebinar 25
- 26. Copyright © 2016 Alchemy Systems How do you measure food safety culture? #alchemywebinar 26
- 27. Copyright © 2016 Alchemy Systems Strategies for Closing the Gaps #alchemywebinar 27
- 28. Copyright © 2016 Alchemy Systems 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 #alchemywebinar 28
- 29. Copyright © 2016 Alchemy Systems Sharing the ‘Why’ 29
- 30. Copyright © 2016 Alchemy Systems Effective metrics – leading and lagging indicators #alchemywebinar 0% 10% 20% 30% 40% 50% 60% 70% 80% Employee turnover Cost per employee Level of safety culture Production output Number of employees trained Manufacturing defects Product safety Employee performance Product quality 30
- 31. Copyright © 2016 Alchemy Systems Who is responsible for training integration? #alchemywebinar 64% 11% 8% 8% 6% 2%1% Job function QA/QC Technical HR Other Operations External provider Regulatory affairs 31
- 32. Copyright © 2016 Alchemy Systems 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 #alchemywebinar 32
- 33. Copyright © 2016 Alchemy Systems Rolling thunder – keeping training top of mind #alchemywebinar 0% 10% 20% 30% 40% 50% 60% 70% Other Paycheck stuffer Digital messaging Newsletters TV monitors E-mail Bulletin boards Posters Team meetings Supervisor communications 33
- 34. Copyright © 2016 Alchemy Systems Rolling thunder - keeping safety top of mind… Huddle Guide Poster + + + Digital Signage Coach 34
- 35. Copyright © 2016 Alchemy Systems Impact of 24/7 awareness on retail food chain 35 0.0% 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% 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Effects of Reducing the Communications Program in Weeks 9 thru 19 Store Audit Scores Week Number
- 36. Copyright © 2016 Alchemy Systems Employees are your best line of defense • Learning – Consistency • Communications – Drive retention through reinforcement • Performance – Coach and observe employee behavior on the production floor 36
- 37. Copyright © 2016 Alchemy Systems 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 #alchemywebinar 37
- 38. Copyright © 2016 Alchemy Systems 38 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 Webinar Recordkeeping & Documentation: Best Practices for Compliance
- 39. Copyright © 2016 Alchemy Systems Q&A 39#alchemywebinar
- 40. Copyright © 2016 Alchemy Systems THANK YOU Global Food Safety Training Survey available at: www.alchemysystems.com New BRC resources available at: www.brcglobalstandards.com #alchemywebinar
Editor's Notes
- Need for benchmark data: How does my training programme compare to others on a global scale? •4th Annual Global Survey by Campden BRI and Alchemy in partnership with BRC, SGS, SQF, TSI •Sent to over 25,000 sites world-wide Sent to over 25,000 food industry sites world-wide
- Food company managers and executives around the world generally agree that effective employee training can have a direct impact on food safety and product quality. In fact, survey respondents noted that the top three benefits from effective training are: improved food safety culture, improved product quality, and fewer food safety incidents (Figure 1).
- In a further effort to boost product quality and food safety, companies are covering a broad spectrum of food safety topics from allergens to sanitation (Figure 4). GMPS, Personal Hygiene, Sanitation/Cleaning Food Safety Culture, Recalls, Internal Auditing
- How is it possible that despite the resources and commitment, 62% of companies have frontline employees who do not actually follow food safety practices?
- Companies are devoting significant time to food safety training. About 74% of employees get four or more hours per year of training per year. For Supervisors/Managers, 52% get nine or more hours of training per year (Figure 3).
- Food companies are increasingly driving food safety training across their supply chains by requiring their raw materials suppliers, service suppliers, and equipment suppliers to undergo food safety training (Figure 5). The caveat is that only 56% of companies are training temporary staff – leaving up
- Tell me about the module you have developed
- Consider how the way we work has changed in the last two decades. In 1986, when the youngest Baby Boomers entered the workforce, the percentage of knowledge necessary to retain in your mind to perform well on the job was about 75 percent (according to research by Robert Kelley). For the other 25 percent, you accessed documentation, usually by looking something up in a manual. In 2009, only about 10 percent of knowledge necessary to perform well on the job is retained — meaning a myriad of other sources must be relied upon. It’s no wonder that those who enter the workforce now have devised new tools and ways of working with each other to deal with the complexity, such as a query through Facebook to their trusted friends. (Even if it’s blocked on the company network, Millennials will connect via mobile devices when they are stuck on projects.)
- A growing number of progressive companies are leveraging leading indicators like employee behaviors to ensure that their employees are not only retaining what they learned in the classroom, but also demonstrating correct behaviors and habits on the plant floor. Comprehensive verification of employee behaviors through plant floor observations, once thought to be too time consuming and impossible to manage, is now available through technology
- Refresher training is an emerging area of research on modifying behaviors. Most people are familiar with the concept of “moving down the learning curve.” There is a corollary curve called “the forgetting curve” – the amount of training forgotten over time (Figure 12). According to Dr. Kohn, people forget 90% of their training within a week.
- ‘One and Done’ doesn’t get it done anymore! Need ‘Rolling Thunder’ Extends learning onto the plant floor Utilizes and engages the Supervisor #1 driver of employee perception of a great workplace is a belief that ‘management cares for me as a person, not just an employee’. * Provides reinforcement Captures the outcome Because it works!!
- At Alchemy, we believe in unlocking the potential of your frontline workforce. Your employees are front and center every day, so they are your biggest asset in keeping your facility safe. We should be consistently teaching employees correct behavior, reinforcing that information through communications, and then coaching and observing employees on the production floor to ensure they are retaining what they have been taught. If your employees know what to look out for and they feel comfortable bringing their concerns to Supervisors or Managers, then they can help you prevent food fraud from occurring in the first place.
- Consider how the way we work has changed in the last two decades. In 1986, when the youngest Baby Boomers entered the workforce, the percentage of knowledge necessary to retain in your mind to perform well on the job was about 75 percent (according to research by Robert Kelley). For the other 25 percent, you accessed documentation, usually by looking something up in a manual. In 2009, only about 10 percent of knowledge necessary to perform well on the job is retained — meaning a myriad of other sources must be relied upon. It’s no wonder that those who enter the workforce now have devised new tools and ways of working with each other to deal with the complexity, such as a query through Facebook to their trusted friends. (Even if it’s blocked on the company network, Millennials will connect via mobile devices when they are stuck on projects.)