Up Front

The value of self-inspections seems to have again taken on an importance in food processing. Facilities want to validate their programs and preventive controls. However, one common mistake I have noticed is that plants have gotten in the habit of scheduling self-inspections during the first shift Monday through Friday. How do they know what is happening during the second or third shift? Do they know what happens during the down period on maintenance and sanitation shifts?

I have received many excuses as to why self-inspections aren’t scheduled during these shifts. The two most common reasons are that their auditors only come in during these periods, and they are preparing for an audit, or they simply don’t like spending their weekends or evenings at the facility. But food safety is a 24/7 responsibility. How can you be confident that the programs created, the policies established, and the sanitation and preventive maintenance programs developed are being accomplished if they are only inspected during normal business hours? Are you relying on records alone?

When I first started inspecting food plants, it was common for first shift to place the blame for an issue I pointed out on another shift. Most often, plants blamed the issue on a lack of training or supervision during these shifts. So, I decided to arrive during second and third shift to see for myself and generally found that they were wrong. In fact, these shifts often seemed to perform better than the first! Each time I arrived during one of these shifts, the employees and supervisors were shocked to see me, yet eager to ask questions about how they could improve and solve problems. It was always a positive experience for me and them.

These experiences often also clarified how some failures occurred or how, with a little more supervision and guidance, possible failures could be avoided. I have had numerous discussions with maintenance departments on how just a small design change or installation could assist in future cleaning activities. I have met with receivers at docks that never really understood what they were looking for when a truck pulled up to the dock. They would follow the procedures, but with a little explanation as to why these procedures were critical, they took on a new attitude of the importance of their job.

It’s not necessary to spend every weekend or every evening in the facility, but you do need to schedule some time so that you are aware of the issues present. Issues always vary between shifts, days of the week, month to month, etc. Self-inspections should be scheduled during every activity and every variance the process and schedules create. How else can you be confident that your programs are working?

The author is Vice President of Food Safety Education, AIB International.