Tuesday, August 9, 2016

Management Commitment 2 of 2 - The Front Line.


Upper management may have commitment (HR support, Capital expenditures, Participation in audits, etc) and the staff have the commitment (seen through the willingness to send you reports on things like foreign material that was caught during production or by washing their hands without being nagged), but without the front line managers involvement, the food safety program can been seen as not integrated into the daily operations or daily non-conformances to policy and procedures. Commitment is essential for the establishment and integration of food safety in any food processing facility. 

What is Front line management doing and showing for their part of management commitment to food safety?  The lack of front line commitment includes paperwork (supervisor audits) not being completed, poor attitude being given to the FSM and QA/QC staff, the general excuse of I did not see the issue, or the “but this audit is getting in the way of us producing” being given.  Note, Food safety vs productivity is NOT an “and/or” situation, it must be seen as two sides of the same coin.  So, how do we get the front line managers/supervisors to commit to food safety when they see their major role as produce – produce - produce?

The first step to change this, and to create an effective food safety culture is to make the front line management aware of the necessity for giving them responsibility for food safety (this includes getting their input).  Awareness through telling them about the need for commitment, training, and completion of audits such as daily GMPs are great ways to accomplish this first step.  It can be scary and off putting for the front line managers if you outright tell them that they lack commitment to food safety (this does depend on the company and involved).  Some may be fine with the bluntness, some will react by finding excuses and generally digging in their heels.  As a FSM you will need to be prepared to deal with this type of conflict.  Remember, the underlying reason is to foster food safety awareness and commitment on a daily basis. As creatures of habit the daily commitment will become habit and ingrained into the managers and staff.

The next step is to foster the awareness and commitment by placing a KPI in place, for example, GMP completion rates by individual managers.  Basically the more GMP audits being completed the more management is looking at the facility conditions and correcting issues and behaviors. The higher completion rates equal higher attention to food safety (neat little canary in the coal mine scenario- isn’t it?). Other KPIs for front line managers could be % training completion. You will get a sense of where your commitment is through the measured results of the KPIs.  As stated above, this commitment is fundamental to establishing the SQF program or any GFSI / food safety scheme in general. I will even go a bit further and say attaining Management commitment is fundamental the effective food safety integration into daily food processing activities. That is the goal and you will need a plan. The plan is how you get there in the short term and long term:

  1. Kick off meeting to get initial buy-in. Be blunt if you can, but definitely give the management team an honest state of the union speech.
  2. Set KPIs –if you cannot measure, how do you know where you are or what you are doing?
  3. Set a time line –short term and long term.
  4. Hold people accountable for their part of the program.
  5. Making needed resources available –HR, structural, Food Safety, whatever is found to be required.
  6. Adjust and build as you go. 
 
The above is a positive proactive approach to fostering commitment to food safety.  Unfortunately there will come a time when an employee or manager is unwilling to commit or comply with the food safety policies and procedures.  At these times another method may need to be used.  Progressive discipline and the company’s willingness to let a person explore other opportunities should be considered.  Sometimes it is better to cut off a rotten branch to save the tree.

Monday, April 11, 2016

Management Commitment Part 1 of 2.

 
Part 1 of 2: How do you know you have management commitment?
 
Fine. You have GFSI audits. You get your scores (minor non-conformances
around 10-15). One of the non-conformance item that keeps coming up is Management Commitment. What is it / what does it look like / how do you know you have it or need to make it better?
 
Defined in SQF edition 7.2 The level of commitment, support, and leadership demonstrated by senior company and site management is fundamental to the effective implementation of an SQF food safety management system. Senior management must create the environment within the facility that encourages a pro-active attitude amongst staff towards food safety and (at Level 3) quality. It the further explains the need for the creation of a policy statement and what the responsibilities of the senior management are.  While this is good stuff, it does not tell us how to achieve said commitment.
 
How does the FSM know management commitment is lacking and how does it look?
 
The basic answer is the daily state of the facility. Unkept production area (like using equipment as coat hooks or corrugate stacking area), off hand comments that show disrespect to food safety (like go do your little tests or I don’t have time or your being a hypocrite by pointing this stuff out and not fixing it yourself), Feeling of isolation on the part of QA/QC staff, Lack of details (or missing pieces) on paperwork/audits.
 
Notice what I am not saying?
 
"we must produce numbers?!"
 
Production must occur and businesses need to grow.  Production needs to grow with food safety. What is Upper Management doing for food safety commitment? Firstly they hired you!, they give you support by agreeing to your safety measures, when financial resources are needed they are given, the Food Safety Policy statement is written and signed yearly. All this is great and needed. 
 
Two items not listed include upper management doing the same things that the employees are doing. Sure you have gone to your boss (VP / Director / or upper management title) and told him they were seen without a hairnet, with their smock open, or watch on and this cannot occur. You were even treated respectfully when you had this talk. The point is, you had to have this talk. Until the upper management and owners do exactly what the employees do, their commitment is not there on a personal level. The front line managers and staff will see this and say - if they don’t care why should I!  In short, upper management not only needs to walk the walk and talk the talk -- they have to do it all the time (especially when they think no one is looking).
 
The second need is for management to make a plan. It is wonderful that upper management says "Food Safety is what we are about" or "we will be audit ready all the time". But, how do you get there? There needs to be a plan with short and long term, tangible goals. They need to consider what a Food Safety system should look like in the real world of a food processing facility and why food safety is important. Each goal on that plan must be measurable with something like a KPI that can be shared.
 
Part 2 - Middle / front line management commitment and what "the plan" could look like.

Saturday, March 19, 2016


Quick KPI for Food Processors

Small / new company?  Tight on resources?  How do you get a handle on where you are at with your food safety program and the culture that is in your building?  KPIs (Key Performance Indicators) can fill this need.  You don’t need to purchase a system (using excel can be very powerful), but you do need to analyze the data that you collect.  True – a third party audit will tell you where you are with regards to your food safety plan but knowing where your challenges lie before an audit (regulatory or not) is huge to the bottom line.  Why wait for an annual audit when a KPI can tell you where you are at on a weekly / monthly basis.

Step one is to collect data.  Depending on what your process is, this can change – you will know what kind of information is needed to gather (you most likely collect many types of information, pick 2 or three to become your KPIs).  Just make sure that the information is “important to you” and is “actionable”.  Important in the respect that the information can tell you how your business is doing.  Actionable in the respect that, good or bad, you can make changes based on the information.  Example – customer complaints.  Trending customer complaints tell you how your business and brand is being perceived and what issues are not being caught before leaving your door.  These complaints are also actionable in two ways;

1.       Short term – feedback on any issues with your product.  Did some-one find a bolt in the product – where did that bolt come from?  Is your equipment is good repair? Is it a onetime incident or do you have a larger problem?  Are your metal detectors working properly?

2.       Long term – trending of information can show you if you have something that can be looked into for improvement.  Complaints of underweight product for example.  Do you need better weigh scales, more employee training, better calibration? Are your customer complaints very low and can be used as a marketing advantage?

Step two is to analyze the data.  Simple is best when you first start doing KPIs.  Say you are doing a weekly GMP checklist/audit.  Summarize all the infractions that you find.  See if you see the same issue day after day.  Create a pie chart to view the result.  Look at the charts from month to month to locate trends.  Example – an overall 20% reduction in hoses being left on the floor from September to December.

Step Three is to share this information.  Post it, have regular meetings, talk about them, publish an internal newspaper with the information on it.  Be as transparent as possible – good or bad your employees will want to know what is going on.  Poor trends can be made into actions – retraining your production staff on calibration of metal detectors.  Good trends can be a basis for appreciation events – pizza lunch, gift card, etc.  Even if it is a thank-you and a hand shake from the CEO, the employees will see this and appreciate it. Be creative!

Moving forward with the KPIs.  Make sure that it is not just one person collecting / analyzing / sharing the information.  Make it a cross-functional group.  Doing this will further breed team work and foster an effective food safety culture.   If management sees these things as important to the business so will the workers.

 

General KPIs that can be created:

1.       Customer Complaints.

2.       Housekeeping  and GMP audits

3.       Audit scores

4.       Waste rates

5.       Reject amounts

6.       Internal foreign material catches

7.       Pest control trends

8.       ATP results

9.       Finished product micro reports