Emily Newton, Revolutionized Magazine
Retail Food Safety Forum

How Does Inventory Management Technology Improve Restaurants?

By Emily Newton
No Comments
Emily Newton, Revolutionized Magazine

Inventory management can be a challenge for restaurants. Stock often moves quickly, many ingredients have short shelf lives and limited storage space can make it easy to overlook some items. Manual tracking methods fall short of modern establishments’ needs, but technology offers an answer.

Inventory management software has made waves in warehousing and logistics, but the food and beverage industry can capitalize on it, too. Restaurants already recognize the need for tech adoption, with 100% of surveyed establishments increasing their urgency to adopt transformational technologies. Inventory tracking solutions should be part of that trend.

This article reviews how inventory management technology can improve restaurants.

Preventing Food Waste

One of the most important parts of inventory management is reducing waste. Up to 10% of food restaurants buy is thrown out before it ever reaches the consumer. Part of this comes from wasteful preparation practices, but much of it results from improper storage.

Inventory tracking technology addresses this issue by increasing stock visibility. In a traditional setup, restaurant employees may not be able to see what they have on hand, causing them to overlook items and leave them until they expire. Tracking technologies provide real-time data about everything in storage and consolidate it into a single, easily accessible window.

Many inventory software solutions include expiration date tracking, alerting workers when something is about to expire. They can use these technologies to find the product in question and use it before it goes bad. Trends over time can reveal if restaurants order too much of one item, driving managers to buy less to prevent waste-causing surpluses.

Avoiding Stock Shortages

Similarly, inventory management solutions can help avoid product shortages. Since the items restaurants order typically don’t go directly to the consumer, it can be difficult to understand stock levels in real-time. The visibility inventory tracking systems provide counteracts that.

Inventory software solutions can maintain real-time inventory data and alert managers when levels get low. They can then order more of a product before they run out, maintaining higher customer satisfaction. Perhaps more importantly, as restaurants use these systems over time, they can highlight seasonal trends to create more accurate forecasts.

Inventory trends will reveal how items grow and shrink in demand at various times of the year. Restaurants can then plan to order more or less of those products at different times according to those trends, avoiding shortages from under-ordering in-demand items.

Consolidating Multiple Sales Channels

Selling through multiple channels can make it more difficult to track inventory levels. Restaurants may use separate systems to manage online and in-person sales, which can lead to confusion and miscommunication.

Inventory management solutions can track online and retail sales together through a single platform. That way, restaurants have a consolidated view of all sales and history, eliminating the miscommunication that arises with traditional methods. Establishments that use a single system for all channels won’t accidentally sell out-of-stock items.

This consolidation also helps refine seasonal adjustments. Online sales trends fluctuate just as they do in person, but there may be some differences. Managers that look at seasonal trends across both channels can adjust their ordering schedules more accurately, further preventing stock shortages.

Highlighting Potential Issues

Restaurants can also use these technologies to review trends over time and highlight persistent issues. Inventory software may reveal that an establishment consistently loses one product because it passes its expiration date. This suggests that it orders too much of it at once, so it can start buying less to adapt.

Similarly, trends can reveal if something is wrong with the restaurant’s storage solution itself. Data could show if ingredients in one refrigerator consistently expire despite accurate ordering figures, suggesting the fridge fails to maintain a safe temperature. These situations are likely and deserve attention, considering that foodborne diseases cause 48 million illnesses a year, according to CDC estimates.

The longer restaurants use these technologies, the more data they’ll have, generating a growing information pool can then inform increasingly precise and reliable forecasts and mitigation strategies.

Calculating Accurate Profit Margins

Another overlooked benefit of inventory management technology is its utility as a financial planning tool. As much as 75% of restaurants struggle financially due to food costs. They may not be able to control ingredient prices, but they can manage them better with accurate inventory data.

Food prices fluctuate rapidly, leading to uneven profit margins. Restaurants that don’t have a granular picture of how their inventory moves won’t be able to calculate their profit margins accurately. Inventory management solutions provide a more granular look into stock levels and offer the context managers need for these calculations.

Inventory tracking technology allows restaurants to view stock movements weekly or even daily to compare with fluctuating prices. This specificity will help get a more accurate picture of expenses and profits.

Inventory Management Tech is Essential

Restaurants must become more financially agile to stay afloat amid widespread disruptions. Inventory management systems offer the insight and control they need to refine their processes, enabling that flexibility, and helping them adapt to incoming changes to ensure future success.

Susanne Kuehne, Decernis
Food Fraud Quick Bites

The Interrupted Supply Chain Of Crocus Sativus

By Susanne Kuehne
No Comments
Susanne Kuehne, Decernis
Saffron, food fraud
Find records of fraud such as those discussed in this column and more in the Food Fraud Database, owned and operated by Decernis, a Food Safety Tech advertiser. Image credit: Susanne Kuehne.

Iran is producing the lion share of saffron, the most precious spice, worldwide. One kilogram of saffron requires weeks of backbreaking work and the manual processing of around 170,000 flowers. Smuggling of what is also called “Red Gold”, and fraudulent and counterfeit saffron, are now million-dollar endeavors, as revealed by Europol and other investigations. From illegal food dyes like lead chromate, to herbs, to corn-on-the-cob strings, saffron is adulterated in many ways to enable fraudsters a participation in this $500 million market.

Resource

  1. Milmo, C. (January 22, 2022). “Saffron: How the lustre of Iran’s ‘red gold’ is threatened by smuggling and counterfeiting as sanctions bite”. iNews.
Susanne Kuehne, Decernis
Food Fraud Quick Bites

Mystery Meatballs

By Susanne Kuehne
No Comments
Susanne Kuehne, Decernis
Meatballs, food fraud
Find records of fraud such as those discussed in this column and more in the Food Fraud Database, owned and operated by Decernis, a Food Safety Tech advertiser. Image credit: Susanne Kuehne

Food fraud is rampant in pre-packaged and non-prepackaged meatballs, according to the Consumer Council in Hong Kong. A DNA investigation of beef meatballs revealed that 60% of samples contained pig derived meat, other samples contained chicken. None of the analyzed lobster ball samples showed any crustacean DNA. Consumers, especially ones with dietary or religious restrictions, are cautioned to check the ingredients lists of pre-packaged meatballs carefully and to be aware the some of the meatballs may contain undesired mystery meat.

Resource

  1. CHOICE Magazine. (January 17, 2022). “Caution for Meatball Lovers — 45 Samples High in Sodium Pig DNA Found in 60% Beef Balls and Beef Tendon Balls Crustacean DNA Absent from All Lobster Balls”. Hongkong Consumer Council.
Emily Newton, Revolutionized Magazine
FST Soapbox

Packaging Automation Can Be an Essential Tool for Food Manufacturers

By Emily Newton
No Comments
Emily Newton, Revolutionized Magazine

Food and beverage manufacturers face various challenges—including a labor shortage, rising demand and ongoing supply chain disruptions. Food packaging automation can be an essential tool for these businesses, as the technology can improve manufacturing productivity without hiring additional workers.

As demand continues to rise over the next few years, and as the labor shortage continues, packaging automation will likely become more important. This is why manufacturers are turning to the technology and how innovations in Industry 4.0 solutions may reshape food manufacturing this decade.

Food and Beverage Manufacturers Are Doing More With Less

Food manufacturers face the same market challenges that most companies are navigating right now. Even two years after the beginning of the COVID-19 pandemic, the supply chain remains unstable, demand is volatile and job openings continue to outstrip available workers.

Consumer expectations are also changing. A growing segment of American shoppers expects businesses to deliver items faster than ever, putting greater pressure on manufacturers to accelerate production and logistics operations.

These trends aren’t likely to reverse anytime soon, even as the pandemic eases and vaccines become available globally. Some experts predict that the labor shortage may be on track to last for years, and the lack of essential raw materials or components may similarly drag on well into the future. This means hunkering down and attempting to weather current market conditions will not be an effective strategy. Instead, businesses will have to experiment with new ways to improve productivity, reduce operating costs and accelerate delivery times.

Automation may become an essential strategy, especially for food and beverage manufacturing tasks that have traditionally been time-consuming and challenging to automate.

How Food Packaging Automation Helps Manufacturers Stay Competitive

Manufacturers that need to increase factory throughput may struggle to bring on additional labor necessary to improve production. Instead, solutions that help them increase productivity without hiring—like packaging automation—may help companies meet existing demand.

Packaging automation tools allow manufacturers to automate various tasks that are tedious, dull, time-consuming and potentially dangerous.

Industry 4.0 technology also allows packaging solutions to automate work that previously required human labor. For example, AI-powered automation systems can use machine vision—algorithms that enable machines to “see” objects — for quality control and manufacturing purposes. These systems may be able to automatically package items or visually inspect them for defects, allowing businesses to improve quality control processes without the dedication of additional labor.

Food packaging automation can also help make food and beverage products more consistent and safer for workers and consumers. Quality control processes are often tedious or repetitive. Throughout a shift, workers assigned to these tasks tend to slow down and make mistakes, potentially allowing defective or dangerous products to move further along the production line.

Automated packaging systems are remarkably consistent when well-maintained. They can run for hours at a time without the same risks that may come with human workers assigned to tedious or repetitive tasks.

Some internet grocery retailers are also using a combination of AI and RFID to improve package branding and drive sales. RFID allows businesses to embed unique identifiers into the packaging of every product they sell, making it possible to collect deeper information about consumer demands and purchasing habits.

Other AI systems use IoT devices that gather real-time data on equipment operations to streamline or automate maintenance checks. For example, a predictive maintenance approach uses AI forecasting algorithms and IoT data to monitor machines and predict when they will need maintenance. The approach is similar to preventive maintenance but is more effective at keeping machines online. In practice, the forecasting power of a predictive maintenance algorithm can reduce downtime and maintenance costs.

Similar AI technology can also be used in the packaging design process. An AI algorithm trained on a library of packaging data may be used to create new packaging—helping businesses identify novel options when it comes to shape or material choice.

Other Advantages of Packaging Automation

Reducing the cost of packaging can also allow manufacturers to spend more money on higher-quality food wrapping—which can, in turn, improve customer satisfaction and drive revenue. For example, many manufacturers have begun to offer eco-friendly packaging materials that can be customized with branding elements. These packaging materials will attract customers who want to buy products from eco-friendly brands. They will also help manufacturers build deeper client relationships while growing additional company awareness.

Over time, these decisions can help a business transform its packaging into a branding tool. This will require an additional up-front investment, but the improvements will pay for themselves over time.
Packaging Automation Can Help Food and Beverage Manufacturers Adapt

Cutting-edge industry technology has made packaging solutions more effective than ever. The right equipment allows food and beverage manufacturers to automate various packaging, design and maintenance tasks—making individual facilities and businesswide processes much more efficient.

Eric Weisbrod, InfinityQS
FST Soapbox

Quality in the Cloud: 5 Tools to Remedy Food Safety Fears

By Eric Weisbrod
No Comments
Eric Weisbrod, InfinityQS

The food and beverage industry has seen a big push for digital transformation over the past several years. Consumers and regulators alike are demanding increasingly high levels of safety and traceability across the global supply chain—driving food manufacturers to modernize their approach to quality control.

Now, many are looking to retire outdated software or inefficient paper-based systems that limit visibility across their production lines, plants and supply chains. They are exploring modern tools that enable proactive quality and safety monitoring. And fortunately, cloud technology is making this shift easier than ever.

Cloud-based quality management solutions offer simple deployment, rapid scalability and low up-front costs—breaking down many of the barriers to digital transformation. Food manufacturers gain anytime, anywhere access to critical resources needed to maintain product quality, ensure compliance and drive continuous improvement across their organizations.

To make it all possible, food manufacturers should select a cloud-based solution that offers the following features and tools.

1. A centralized data repository for improved visibility, compliance and collaboration

In a traditional manufacturing environment, quality and process data are locked away in paper files, Excel spreadsheets, or on-premises software. These data silos prevent manufacturers from monitoring enterprise-wide quality performance, and inhibit data sharing with external parties across the supply chain.

But the cloud can break down those silos. Cloud solutions provide a single, unified data repository where food manufacturers can standardize and centralize quality data—from all processes, production lines, and sites in their enterprise, as well as from suppliers, co-packers and third-party producers.

The resulting “big picture” view of quality enables food companies to:

  • Perform enterprise-wide analyses to pinpoint problem areas, identify best practices, and prioritize resources—ultimately improving quality and compliance across the entire organization.
  • Verify ongoing regulatory compliance and enforce accountability for all required checks and tests.
  • View supplier data in real time to prevent food safety issues and ensure incoming ingredients meet quality standards before they are ever shipped. Only the highest-quality ingredients get accepted and incorporated into products.
  • Monitor supplier performance to better manage suppliers and prevent supply chain disruptions.
  • Collaborate with contract manufacturers and packers to make sure they uphold quality standards and protect the brand.

2. Real-time SPC for proactive response on the plant floor

A preventative approach to quality and safety just isn’t possible when using manual methods for data collection and analysis. Operators spend valuable time recording data with a pencil and paper, then sift through page after page of control charts—on top of all their other daily responsibilities. It’s easy to see how mistakes could be made and production issues could be missed.

Quality teams are also at a disadvantage, reviewing old data about products that have already come off the production line. Overall, everyone operates in “firefighting” mode. They try to fix one issue after another, but it’s often already too late. Some problems may not be spotted until final inspection, if even caught at all. Manufacturers end up dealing with defective products, wasted resources, and damaging recalls.

The cloud transforms how food manufacturers collect and analyze quality data. Cloud-based statistical process control (SPC) software can automatically collect measurement values from a variety of data sources, then monitor processes in real time. When the software detects specification or statistical violations, automated alarms instantly alert key personnel. The appropriate teams can take immediate action to correct any issue before it gets out of hand.

In addition, food manufacturers can put up further safeguards on the plant floor with “workflows.” Essentially, these are prescriptive guides for responding to quality issues, predefined in the cloud-based quality solution. They help all employees respond consistently and effectively to specific problems, and then document the corrective actions taken. These responses can then be analyzed across an entire company, allowing manufacturers to spot trends and prevent reoccurring issues.

Ultimately, operators and quality personnel can stay on top of potential problems and prevent unsafe or defective goods from reaching customers—without having to manually monitor every line, in every plant, around the clock.

3. Timed data collections to keep everyone on the same page

Routine sampling and quality checks are critical for food safety and compliance with regulatory and industry-specific standards. But how can manufacturers ensure required checks are completed according to schedule? After all, the plant floor is a busy place and where it’s easy for operators to get sidetracked tackling other issues.

Here, cloud-based quality systems can help. These solutions enable manufacturers to set up timed data collections, which send automated notifications to remind operators when it’s time to perform HACCP, CCP, and other critical quality and safety checks. Operators can stay focused on production, without having to watch the clock or worry about missing a check. Plant supervisors also get alerts if a data collection is missed—no matter where they are working—so they can keep everyone on top of compliance.

4. Digital reporting to make audits a breeze

Every manufacturer dreads the auditing process. It is time consuming and resource intensive, adding another layer of stress and complexity to the already complex nature of food production. Those that rely on paper records and spreadsheets usually struggle to piece together and produce auditor-requested information. And failed audits can have major consequences.

Instead, quality records and other compliance documentation can be digitized, stored and made quickly accessible via the cloud. This makes it easy for food companies to pull historical data for specific timeframes. Reports can be produced in just minutes to complete regulatory, third-party certification, or internal audits—rather than the days or weeks it would typically take to put together a report from a complicated trail of paper.

5. Lot genealogy for improved traceability and recall response

Recalls are another big source of stress for food manufacturers. After all, food quality or safety incidents that result in a recall not only hurt profits and brand reputation, but also put the health and lives of consumers at risk. Fortunately, recalls can be mitigated or avoided through better traceability.

Cloud-based quality solutions can help food companies trace raw ingredient lot codes through the manufacturing process and supply chain. With all quality data stored in that centralized cloud repository mentioned earlier, manufacturers can generate genealogical “trees” showing the relationship between incoming ingredients and outgoing products.

This information in critical for preventing and responding to product recalls. If a safety issue is found within a specific ingredient lot, for example, manufacturers can quickly identify output lots where those ingredients were used. They can prevent those finished lots from being released, or in the worst-case scenario, remove those lots from store shelves in a swift, targeted recall.

A Tactical Approach to Digital Transformation

Looking at the FDA’s New Era of Smarter Food Safety blueprint, it’s clear to see that the industry at large is heading towards a new digital age. Food manufacturers shouldn’t wait to take the first steps, and cloud-based quality can get them on the right path.

While any big change comes with hesitancy, a tactical approach can help ease any fears. Some food manufacturers have started with small-scale projects, deploying cloud-based quality solution to monitor a single process or production line. Leadership teams and employees alike can see how quality in the cloud benefits everyone at all levels of their organization—and then deploy the solution on a wider scale. It is a great way to successfully introduce new digital technology and lay the foundation for future transformation.

Rick Biros, President/Publisher, Innovative Publishing Co. LLC
Biros' Blog

What Is the Current State of the Food Safety Industry and Where Is It Going?

By Rick Biros
No Comments
Rick Biros, President/Publisher, Innovative Publishing Co. LLC

COVID-19’s impact on the food safety community has been significant and its impact will continue to be felt for years.

While FDA inspections and supplier audits are resuming, one cannot assume that the food industry is going back to 2019 or even that it should. It’s time for a food safety reboot or Food Safety 2.0.

Call it what you want, the industry must not only adapt to the “New Normal” but strategize on how to navigate through new challenges, including supply chain capacity and diversity of capacity, workforce welfare and retention, food defense and cybersecurity, food integrity, increased need for traceability, climate change’s impact on food safety, new challenges in supplier audits and compliance, mentoring and developing the future FSQA Leaders and lastly, the next regulations.

The goal now is not to get food safety back to 2019 levels but to build it better. These issues must be discussed among peers and best practices must be shared. You can’t do that in a webinar or in the traditional conference setting of didactic “death-by-PowerPoint” lectures.

To help facilitate this much needed critical thinking and meeting of the minds, the 10th annual Food Safety Consortium Conference, managed and curated by Food Safety Tech is back to an in-person format, October 19–21, 2022 at the Hilton Parsippany, New Jersey (20 minutes from Newark Liberty Airport and 29 miles outside on New York City).

With a capped audience of 250, the 2022 Food Safety Consortium Conference program has been designed to encourage true peer-to-peer networking and sharing of best practices. The program features many discussion groups including “The Days FSQA Professionals Fear the Most,” “Strategic Challenge: Engagement of Management” and “What is the current state of the food safety industry and where is it going?”

You will not just attend the Food Safety Consortium, you will actively participate in the program that features strategic and critical thinking topics that have been developed for both industry veterans and future FSQA Leadership.

I hope you can join us and participate in the meeting of the minds in October.

Susanne Kuehne, Decernis
Food Fraud Quick Bites

You Can’t Change Your Fingerprints

By Susanne Kuehne
No Comments
Susanne Kuehne, Decernis
Olive Oil, food fraud
Find records of fraud such as those discussed in this column and more in the Food Fraud Database, owned and operated by Decernis, a Food Safety Tech advertiser. Image credit: Susanne Kuehne.

In the European Union, extra virgin olive oils must be labeled with their geographical place of origin. The provenance of olive oil can now be verified with newly developed method involving the analysis of extracted sesquiterpene hydrocarbons via gas chromatography and mass spectrometry. The method is highly precise and at the same time inexpensive. Sesquiterpene hydrocarbons are found in many live organisms and show characteristics based on olive tree cultivars and where the trees are grown, leading to a precise olive oil origin fingerprint.

Resource

  1. de Andreis, P. (February 9, 2022). “Hydrocarbon Fingerprinting Helps E.U. Researchers Verify Olive Oil Provenance”. Olive Oil Times.
Karen Everstine, Decernis
Food Fraud Quick Bites

Best Practices in Setting Up Food Fraud Programs

By Karen Everstine, Ph.D.
No Comments
Karen Everstine, Decernis

In 2016, the food authenticity team at Queen’s University Belfast published a study that evaluated adulteration levels in oregano—specifically, 78 samples purchased at retail.1 Almost a quarter of the samples had some adulteration. Some samples actually contained more than 70% other leaf material, primarily olive and myrtle leaves. This study was widely reported and appeared to result in drastic decreases in the levels of adulteration in oregano.

However, just last year, the Joint Research Centre of the European Commission published the results of a coordinated control plan for “fraudulent practices” in spices in which they tested 1,885 samples of 6 herbs and spices submitted from from 23 countries.2 Almost half of the 295 oregano samples were “suspicious of being adulterated.” The results of these studies imply that food fraud—especially fraud involving higher-value and further-processed products with a substance that does not make consumers sick—is a persistent risk and demands a sustained response from industry and regulators.

Evaluating historical data from various sources (the scientific literature, regulatory reports, media reports, etc.) is a critical component of a food fraud prevention program, but it is not enough. A strong program will include an in-depth evaluation of what is known historically about food fraud for relevant raw materials, ongoing monitoring of food safety and fraud notifications, a fraud-focused evaluation of supplier controls, audit and testing programs that include specific anti-fraud measures, and an assessment of situational factors that could increase fraud incentive (geographic, economic, etc.).

The Food Fraud Database has tracked public reports of food fraud for almost 10 years. Many incidents are types of fraud that have occurred repeatedly, as the incident distribution from last year illustrates (see Figure 1). In addition to herb/spice fraud, frequent types of fraud include replacement of honey with sugar syrups; unregulated and counterfeit liquor; wines labeled as a more expensive varietal or with undeclared additives; milk products with added protein or fats from other sources; and fraud related to organic certification or geographic origin. Although these types of fraud appear to be “reasonably foreseeable,” the challenge is that during a time of supply chain stressors—such as the COVID-19 pandemic—risks may evolve quickly as suppliers and supply chain structures change. Re-evaluating food fraud vulnerability in response to changing conditions can be time-consuming, but is important to stay ahead of potential risks.

Food Fraud Incidence
Figure 1. Food fraud incidents reported in public sources, 2021. (Source: FoodChain ID Food Fraud Database)

We frequently work with food manufacturers to develop their food fraud vulnerability assessments. Our experience is that searching and compiling risk data and mapping a set of raw materials to the appropriate data sources for analysis can be the most time-consuming aspects of the project. Since Google searches or other manual processes are not always reliable and efficient, a helpful first step can be finding a data source that compiles and standardizes food safety and fraud data from a wide range of reliable sources. The mapping process then involves identifying each individual ingredient component of the raw materials sourced by the company and linking it to the relevant ingredient name in the data source. It is important to invest this time up front to identify the most appropriate data sources and conduct a thorough mapping process. This ensures food safety and quality assurance staff will be notified of information relevant to their particular supply chains moving forward.

Many quality assurance professionals struggle to fit in food fraud assessments and mitigation plans while managing day-to-day food safety and quality programs. A two-stage process, including an ingredient screen followed by a detailed assessment for potentially high-risk ingredients, can make the process more efficient for companies managing hundreds of raw materials (see Figure 2). Existing food safety testing and auditing programs may also have application to food fraud prevention and should also be documented in a food fraud program. Many food companies find value in outside expert guidance to set up a food fraud program so that food safety and fraud risks aren’t unintentionally missed. The goal of a food fraud program is not to add to the workload of food safety and quality assurance staff, but to enable those staff to identify the most targeted measures that will help ensure food safety, authenticity, and brand protection.

Food Fraud Prevention Program
Figure 2. Components of a food fraud prevention program (Source: FoodChain ID).

References

  1. Black, C., et al. (2016). A comprehensive strategy to detect the fraudulent adulteration of herbs: The oregano approach. Food Chemistry, 210, 551–557. https://doi.org/10.1016/j.foodchem.2016.05.004
  2. Maquet, A., et al. (2021). Results of an EU wide coordinated control plan to establish the prevalence of fraudulent practices in the marketing of herbs and spices. EUR 30877 EN. Publications Office of the European Union, Luxembourg. ISBN 978-92-76-42979-1 (online).
Susanne Kuehne, Decernis
Food Fraud Quick Bites

Wake Up And Seize the Coffee

By Susanne Kuehne
No Comments
Susanne Kuehne, Decernis
Coffee, Food fraud
Find records of fraud such as those discussed in this column and more in the Food Fraud Database, owned and operated by Decernis, a Food Safety Tech advertiser. Image credit: Susanne Kuehne

Twelve thousand packs of adulterated coffee that did not match quality standards were seized in Brazil. The coffee was not labeled correctly, and in addition contained foreign matter, such as bark and wood. This investigation is part of a larger operation that altogether seized 15 tons of adulterated coffee, which contained corn, did not adhere to quality standards, and was packaged with a counterfeit purity seal.

Resource

  1. Brito, J. (January 18, 2022). “De milho a madeira na composição: 12 mil pacotes de café são apreendidos no ES”. Espirito Santo.
Adam Serfas, R.S. Quality
FST Soapbox

Food Safety’s Secret Weapon Against COVID-Related Turnover

By Adam Serfas
No Comments
Adam Serfas, R.S. Quality

The food processing and manufacturing industry is one of many in the United States that is continuing to struggle with attracting and retaining workers. The situation is one that processors have found themselves in for years, but amidst an ongoing pandemic, the problem of labor shortage has rapidly reached a critical mass.

To fill understaffed processing lines, companies have employed a wide range of tactics—boosting wages, dishing out bonuses, announcing better work schedules, and bolstering benefits packages. While these recruiting tactics will get bodies on plant floors, they alone aren’t enough to keep things running smoothly. (And, noticeably, there’s been less chatter around measures that aren’t as public facing.) Inevitably, some employees will continue to fall ill with COVID-19 and need to isolate for periods of time, requiring job function shuffling and the need for temporary workers. Likewise, turnover is predicted to remain high industry-wide as companies continue to compete for a slim labor market. With this tumult will come continued product delays, supply chain disruptions, and the very real risk of critical food safety slipping.

For years now, food processors and manufacturers have looked to color-coding as a method for ensuring quality and preventing product contamination and cross-contamination. Conceptually, the process is simple. By assigning different colors to plant zones, assembly process steps, shift teams, or potential allergens and hazards, workers are able to use the correct, conveniently color-coded tools and products in the way they were intended. The plans are customized by facility but are always framed by four basic models mentioned here. When implemented correctly—and inclusively—a color-coding plan can bring so many benefits to a facility, especially in this moment.

Benefit #1: It’s Easily Recognizable

The point of a color-coding plan is to streamline and systemize food safety and hygiene procedures to minimize risks to the safety of products and team members in a facility. With that in mind, most color-coding plans comprise just a handful of colors, and oftentimes, workers in a plant will only ever interact with one or two. Once a team member learns, “I work in this zone, and I will always use blue tools here; or, I work in this part of the assembly process, which will always use red tools”; it’s pretty easy to remember that guidance.

With the availability of high-quality, hygienic tools in full-color options these days, it is pretty effortless to spot a tool that’s out of place. Additionally, many plants will choose to color-code wearables and PPE such as gowns, masks, and gloves so that it’s immediately obvious when a team member isn’t where they should be. Facility signage also comes into play as it’s a best practice for color-coding to always place descriptive plan signage in sight. Some facilities even put color-coding plans on individual ID tags to ensure it is always at the fingertips of team members.

Benefit #2: It’s Easily Understood

The success of a color-coding plan hinges on marrying design simplicity (meaning as few colors as possible with the most logical categorization), with a robust rollout (where every functional item is color-coded). When these needs are met, the plan is easy to understand and follow. It can help multilingual teams as the language barrier is minimized with a focus on colors vs. terminology, and as these plans are growing in popularity, a new employee with experience in the industry has likely worked with a plant operating under some form of a color-coding plan.

Most importantly, now, a color-coding plan can allow for new employees or temporary workers to get up-to-speed quickly. When turnover and hiring are happening more frequently and training team leaders are strapped for time, this is a game-changer as people can be on-boarded quickly without compromising quality and safety.

Benefit #3: It Doesn’t Rely On One Team Member To Train

It’s never a good idea to have important procedural safety standards of a facility live in just one person’s head. It is especially risky at a time when employees are falling ill and needing to isolate themselves on an ongoing basis.

One of the things that makes a color-coding plan successful is that everyone who works in a facility is involved. The plan only succeeds if everyone understands their unique role in the equation, and because of that structure and expectation, everyone is aware of how the plan should be working in practice. This means training new employees doesn’t only involve a small handful of individuals, allowing the responsibility of onboarding to be shared.

Benefit #4: It Can Boost Morale—Really

It’s no secret that many companies are facing dips in team morale these days. Between an ongoing pandemic and persistent turnover, new stressors are added every workday. This can impact not only job satisfaction for employees while at work but also present a safety risk, as food safety culture truly relies on every person in any given facility.

A color-coding plan sets the tone of teamwork and serves as a reminder of the importance of every individual in the larger goal of keeping every other person and the product safe. That reminder of personal responsibility and impact can go a long way when baseline tensions are up, and workflow disruptions are the norm.

If there’s anything the past couple of years has taught the industry, it is to expect the unexpected and, in turn, use whatever devices you have to make the best out of the current situation. A color-coding plan can help you do just that by serving as one of the best tools at your disposal in this moment.