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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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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!
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Copyright © 2016 Alchemy Systems
Today’s Speakers
John KukolyBRC Global Standards, Americas Director
Laura Dunn NelsonVP of Business Development
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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
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Copyright © 2016 Alchemy Systems
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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Copyright © 2016 Alchemy Systems
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
7
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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
9
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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%
11
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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%
12
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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
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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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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
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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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Copyright © 2016 Alchemy Systems 24
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
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
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
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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
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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
WebinarRecordkeeping & Documentation: Best Practices for Compliance
Copyright © 2016 Alchemy Systems
Q&A
39#alchemywebinar
Copyright © 2016 Alchemy Systems
THANK YOUGlobal Food Safety Training Survey available at:
www.alchemysystems.com
New BRC resources available at: www.brcglobalstandards.com
#alchemywebinar