Implementing SQF Training for Food Safety SuccessFood ... · PDF fileImplementing SQF Training...

Implementing SQF Training for Food Safety SuccessFood Safety Success

© Scientific Certification Systems | 1© Scientific Certification Systems | 1

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


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


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.


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


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.


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


GFSI International Food Safety Standards


Global Food Safety Training 2013


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


Awareness – understand what needs to be done


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)


( )

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.


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.


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…


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.


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


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.


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


Global Food Safety Training 2013


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!


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


Leveraging Your SQF Systemeveraging Your SQF System

© Scientific Certification Systems | 23© Scientific Certification Systems | 23© Scientific Certification Systems | 23

Effectiveness

2.9.7. Training Skills Register


Alignment = Buying In


Food Safety is Educational


Food Safety and Quality

Who is responsible?


Everybody is Responsible!!


Who Needs To Be Trained?


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)


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


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


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


Food Safety d QA P f i land QA Professionals


QA Manager / SQFP


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


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


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


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.


Case Studies


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


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


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


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


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


QC vs. QMS


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


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


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.


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


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


Think of Training as the fuel needed to keep moving forward – on track, safely getting your product where you want it!


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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