Recent news of Salmonella occurrences in dry food processing facilities has made me wonder if better inspection practices would have prevented these events. I am often surprised at how little is understood about the importance of inspecting. While both auditing and inspection are important, many of the new audit schemes and the growing emphasis on recordkeeping and programs often cause employees to ignore the details on the food plant floor. A slight leak from a drainage line, condensate from an overhead vent, or material buildup in a transfer system often are very serious issues that are missed during an audit burdened by recordkeeping and program reviews.
Self-inspection is important in food plants. The self-inspection team is in place to schedule regular inspections, focus on the product and production lines and learn what does and does not work on the floor. AIB suggests that teams schedule their inspections during different phases of the operation, including down time, maintenance and all shifts. Break down equipment and look into maintenance issues, cleaning issues and operational issues that may affect the product or process. It is difficult work, but it is always rewarding. It allows team members to participate and gives them a better understanding of the process on the floor.
By asking questions and answering them collectively, we learn about the operational issues that can affect the process and our product. Working together and involving floor employees whenever possible allows them to become more aware of the production processes and the environments they work in. The self-inspection team should set an example and encourage employees to ask questions and get involved.
Involving all employees in facility inspections is a great learning experience, but this experience is being lost in the process of program reviews, cutbacks and production schedules. There are many excuses for not spending the time needed to do regular, thorough self-inspections. But there is no excuse for not knowing about design faults causing buildup and incomplete cleaning. There is no excuse for not noting the slight leak from an overhead line. And there is no excuse for not understanding the dangers from condensate above a product.
There is no substitute for experience on the floor. We need to get back to the basics. The basics of inspecting are critical to understanding and correcting issues in the facility. Using the ICE concept (Identify. Control. Eliminate.) is essential to ensure that what we believe is happening on the floor is actually happening.
The author is Vice President of Food Safety Education, AIB International.