Bournville Manufacturing GMP Training 2022

Summary

In this 2022 training video, Paul B welcomes employees to the annual Good Manufacturing Practices (GMP) training at the Bournville site of Mondelez. The focus is on maintaining high standards of quality, food safety, food defense, and food fraud prevention. The training covers personal responsibilities, factory practices, safety protocols, and the company's quality policies. Participants must adhere to strict guidelines regarding personal belongings, hygiene, workwear, and material handling. The training emphasizes the importance of reporting symptoms of communicable diseases and following procedures to manage allergens and prevent contamination.

Highlights

• Welcome to GMP training – where quality, food safety, and food defense become second nature! 🎓
• Love our consumers and ensure the highest standards in everything you produce! 💖
• Your ID card is more than just an entry pass; it’s your key to quality commitment! 🛠️
• Keep those hands clean! Handwashing remains the frontline defense against contamination. 👐
• No personal belongings or food past the wash sinks; safety first! 🚫👜
• Always follow the allergen handling procedures to keep everyone safe and healthy. 🥛🥜
• Beware of the little things – lost gloves, misplaced tapes, they can lead to big problems! 🔍
• The right workwear can prevent unwanted surprises in the final product. 😷
• You are the first line of defense against food fraud and misuse. Report any odd behavior. 🚨

Key Takeaways

• Always remember that quality and safety are top priorities – we’re making treats for our loved ones! 🍫
• Know your responsibilities under GMP, food safety, and food defense policies to ensure a safe and quality work environment. 🛡️
• Report any symptoms of communicable diseases before coming to work to safeguard everyone’s health. 🤒
• Strictly follow hygiene rules, including proper handwashing, to prevent contamination. 🧼
• Manage allergens carefully; know the tools and procedures for avoiding allergic reactions. 🚫🥜
• Pay attention to workwear rules; what you wear can directly impact product safety. 👕
• Understand the importance of pest control and keeping entrances closed to deny pest entry. 🐜
• Keep your eyes peeled for food fraud and food defense issues; report anything suspicious! 👀

Overview

The GMP training session kicks off by ingraining the importance of quality and safety right at the entrance of Mondelez’s Bournville site. The values of loving our consumers and doing what's right are emphasized, as every task within the site is for creating products worthy of our loved ones. The introduction invites employees to internalize this ethos every day they step on-site.

Personal responsibility takes center stage as the session delves into what is required from each individual, from hygiene rules that avoid cross-contamination to specifics like not wearing perfumes or jewelry that might compromise product safety. Employees are guided to think like consumers, setting standards high as if they're catering for their own family, and to be vigilant about their own health, especially regarding communicable diseases.

The rigorous standards continue into factory practices, workwear rules, and allergen management. This section offers exhaustive details on the correct attire, tool usage, cleaning practices, and pest control. The training highlights the necessity of following these standards not just to comply with rules but to genuinely care for the consumer’s health and the company’s reputation. From the handling of allergens to preventing pest infiltration, every action taken is framed as a step towards ensuring only the finest chocolate reaches shelves.

Chapters

• 00:00 - 00:30: Introduction to GMP Training The chapter introduces the annual Good Manufacturing Practices (GMP) training at Mondelez, focusing on quality aspects such as food safety, food defense, and food fraud. It emphasizes the importance of understanding and implementing these practices at the Bourneville site. The training underscores the company's quality policy, which aligns with its core values of prioritizing consumer satisfaction and ethical practices.
• 00:30 - 01:00: Quality Policy and Consumer Focus The chapter emphasizes the importance of remembering the consumer while on site, aligning with the motto: 'On site, we create products we're proud to give to our family and friends.' It prompts individuals to reflect on who their consumers are by considering loved ones, family, and friends as consumers of their products.
• 01:30 - 02:30: Responsibilities and Knowledge Checks The chapter "Responsibilities and Knowledge Checks" emphasizes the importance of performing tasks and roles with consideration for family and friends while maintaining high standards for consumers. It encourages making decisions that reflect well on loved ones, and highlights the reciprocal relationship between a company's dedication to quality and consumer appreciation, illustrated by a quote demonstrating the positive impact of the company's products.
• 02:30 - 06:00: Personal Responsibilities in the Factory This chapter introduces the key concepts of personal responsibilities in the context of a factory setting, specifically focusing on GMP (Good Manufacturing Practice) food safety and food defense policies as applicable in Bourneville. It outlines the importance of understanding individual roles under these policies and highlights the learning goals of the training, which is divided into three parts, to equip individuals with the necessary knowledge to meet their obligations effectively.
• 06:00 - 12:00: Hygiene Practices and Health Reporting The chapter discusses personal responsibilities, factory practices, food defense and food fraud, and special situations in the context of hygiene and health reporting.
• 12:00 - 16:30: Factory Workwear and PPE The chapter titled "Factory Workwear and PPE" emphasizes the importance of adhering to Good Manufacturing Practices (GMP) within a factory setting. It concludes with a reminder of the top 10 GMP items that need to be checked every shift. Personal responsibilities are highlighted, including prohibitions within the factory premises such as eating, drinking, chewing, smoking, vaping, or holding objects in the mouth.
• 16:30 - 20:00: Glove Safety and Workwear Management The chapter titled 'Glove Safety and Workwear Management' emphasizes hygiene and safety standards in food handling environments. It highlights the importance of sensory tasting being conducted away from exposed products to prevent contamination, with individuals involved having access to hand sanitation. It advises against wearing perfumes, aftershaves, or strong deodorants that could affect product quality. Additionally, the chapter prohibits the use of false fingernails, nail polish, or varnish, urging staff to maintain short, clean, and unbitten nails for optimal hygiene.
• 21:00 - 23:00: Cleaning and Sanitization This chapter highlights the importance of maintaining strict cleaning and sanitization standards in the manufacturing area. It starts with an example illustrating the horror a consumer experiences when finding foreign objects, like a nail, in their product. To reinforce hygiene and prevent such issues, personal possessions, including items like false eyelashes or lash extensions, are prohibited beyond the hand wash area in the manufacturing zone. The emphasis is on scrutinizing complaints to prevent contaminants and ensure product safety.
• 23:00 - 26:00: Tools and Equipment Handling This chapter focuses on the rules and guidelines for handling tools and equipment, emphasizing areas where certain items are prohibited. These areas include sinks, materials stores, and places where food, drinks, or their empty containers are present, unless exempt by Occupational Health. Additionally, personal electronics like iPads, tablets, wireless headsets, or speakers are not allowed, nor are personal bags, wallets, and cash. Instead, payment methods for amenities such as canteens and vending machines are streamlined for convenience.
• 28:00 - 31:00: Maintenance and Storage The chapter 'Maintenance and Storage' provides guidelines on what not to bring into the workplace. It highlights that ID cards can be topped up online or at canteen tills. Employees are advised against bringing newspapers, magazines, documents with staples, cigarettes, vapes, or additional work tools from home. Personal mobile phones are allowed but should only be used in designated t-bar areas.
• 31:00 - 37:00: Contamination and Pest Control In the chapter titled 'Contamination and Pest Control,' it is emphasized that while mobile phones are allowed within manufacturing areas, they are required to have screen protectors. Additionally, there are strict guidelines regarding items like pens: only factory-approved, metal-detectable pens are permitted, and these must be kept below the waistline instead of being tucked into a jacket or placed behind the ear. This highlights the importance of minimizing contamination risks and adhering to pest control measures in production environments.
• 37:00 - 45:00: Material Management and Allergen Control The chapter 'Material Management and Allergen Control' emphasizes the importance of personal safety and material handling within a facility. It specifically focuses on the restrictions regarding personal items such as jewelry and watches when inside the workplace environment to prevent contamination or safety hazards. Employees are advised to refrain from wearing any jewelry, visible or hidden, except for one plain wedding band if it cannot be removed. Identification cards must be carried below the waist in a holder made of metal detectable plastic. These holders can be acquired from the quality department or security personnel, ensuring compliance with safety protocols.
• 46:30 - 48:00: Food Defense and Food Fraud The chapter introduces the importance of cleanliness and organization in a factory setting, particularly highlighting the significance of changing rooms. It emphasizes adherence to standards by keeping hair nets, beard coverings, and tidiness as a priority. Dirty workwear should be placed in designated cages, separating personal items in a yellow locker while factory workwear and shoes go into a green locker. The practices outlined facilitate cleaning and maintain hygiene within the workspace.
• 48:30 - 51:00: Special Situations and Reporting This chapter emphasizes food safety protocols and personal hygiene in specific areas of a factory. It instructs employees not to eat or store food in the changing room or even in their yellow lockers, and advises that food should be stored in the canteens' fridges. Additionally, it highlights the importance of keeping hands clean through washing, drying, and sanitizing them at all main factory entrances to ensure safe food handling.

Bournville Manufacturing GMP Training 2022 Transcription

• 00:00 - 00:30 welcome to your annual GMP good manufacturing practices training where you'll learn all things quality including food safety food defense and food fraud and what it means to you while you're on the bourneville site at Mondelez we have a quality policy that's displayed on all the entrances to the site this is based on our values of loving our consumers and doing what is right
• 00:30 - 01:00 so that's what you need to do every day when you are on site remember our consumers and remember our motto on site we create products we're proud to give to our family and friends so think about what that means for you who are our consumers who are you making products for we all have loved ones family and friends that consume our products so
• 01:00 - 01:30 whatever task you do whatever role you play do it for them make decisions that are good enough for your family and friends setting the highest standards for our consumers and our consumers share the love back just look at this quote and the impact our products have on the people that consume them
• 01:30 - 02:00 so in this course what you'll need to know is that we have policies for GMP food safety and food defense in bourneville you'll need to under understand your responsibilities under these policies and you'll learn what you need to do in order to fulfill those responsibilities this training is split into three parts
• 02:00 - 02:30 firstly we'll be looking at your personal responsibilities then the practices within the factory and lastly we'll be thinking about food defense and food fraud and special situations after each section there will be a knowledge check and you need to get all the questions right in order to pass on to the next section but don't worry you'll be able to go over the questions that you got
• 02:30 - 03:00 wrong and lastly we'll sum up by reminding us all of the top 10 GMP items that we need to check every shift so firstly your personal responsibilities remember that these things are not allowed within the factory eating drinking chewing smoking vaping or holding any objects in the mouth
• 03:00 - 03:30 we are allowed to carry out sensory tasting in designated areas this is away from exposed products and it's carried up by individuals who have hand sanitation available you're not allowed to wear perfumes aftershaves or strong deodorants as this could taint the product please do not wear false fingernails nail polish or varnish you must keep your nails short clean and not bitten
• 03:30 - 04:00 imagine how horrible it is for a consumer to find a part of a nail in their product and do not wear false eyelashes or lash extensions if you read our consumer complaints over the years you would be amazed at the sort of things our consumers have found in their products and for that reason no personal possessions are allowed within the manufacturing area so that's anywhere past the hand wash
• 04:00 - 04:30 sinks or in any materials store so that includes food or drink or any food empty food or drink containers any medication unless an exemption is detained from Occupational Health not allowed to bring iPads or tablets in or any wireless headsets or speakers please don't bring personal bags in or wallet some cash please note that the canteens and the vending machines accept payments on your
• 04:30 - 05:00 ID card and you can load money onto your ID card online or at the tills within the canteens don't bring newspapers and magazines in don't bring any document that might contain Staples don't bring cigarettes or Vapes don't even bring things from home that might be useful for your job like additional tools a personal mobile phone is allowed but must only be used within t-bars or
• 05:00 - 05:30 production offices business mobile phones are permitted within the manufacturing area but they must have a screen protector and remember even things like pens only Factory approved metal detectable pens must be used and they must be carried below the waistline don't shove them in the top of your jacket or behind your ear
• 05:30 - 06:00 please don't wear any jewelry whether you can see it or not and please do not wear a watch you are allowed to wear one plain wedding band if this cannot be removed your ID card must be carried below the waste and it must be in a holder that's made of metal detectable plastic if you need one of these holders please obtain one from the quality department or from security
• 06:00 - 06:30 first place on site you'll come across is the changing room so please set the standard there keep them tidy hair nets and beards nudes and bins provided and put your Dirty Work wearing cages your yellow Locker is for your personal possessions but the green Locker is just for your factory Workwear and your shoes don't put your dirty whites in there put those in the cages your shoes should be kept in the green locker and not on the floor because it makes cleaning the floor very difficult
• 06:30 - 07:00 and please do not eat food in this area or store food in this area even in your yellow Locker no food to be brought into the changing room it should be stored in the fridges provided in both canteens foreign things we can do to make safe food is to keep our hands clean we should wash dry and sanitize our hands at all the main Factory entrances
• 07:00 - 07:30 there are three main Factory entrances the main molding two changing room the timeout entrance in V2 and the contracts are changing room entrance in V1 we should also wash our hands if we're moving between areas with different allergen profiles or we're going to an area that has no allergens
• 07:30 - 08:00 we should also wash our hands for the other reason shown on the screen just take a moment to digest these after the events of the last two years we should all know how to wash our hands well you can see on the screen the seven sides to the hand that you need to wash before drying and then sanitizing
• 08:00 - 08:30 we also should all know by now how long it takes to get good hand washing about 20 seconds or the time it takes to sing Happy Birthday twice just look at the impact under UV light showing the effectiveness of good hand washing you can see the microorganisms have been removed by good hand washing
• 08:30 - 09:00 one reason we wash our hands is to reduce the spread of communicable diseases communicable diseases are diseases that can be spread by food and if they get into our products consumers could become ill on the screen you can see some of the most common illnesses that fall into this category they are all extremely serious these diseases can kill
• 09:00 - 09:30 and therefore by law it is it is required for food handlers to report conditions which could cause food poisoning This legal obligation to inform the business that you may be suffering from one of these illnesses applies to anyone be it a Mondelez employee a contractor or even a visitor who enters the factory
• 09:30 - 10:00 the symptoms that we all should report are diarrhea vomiting fever abdominal pain dark urine jaundice open skin sores boils or a discharge from the eyes ears mouth or gums you should inform your line manager and occupational health before you leave your house to come to work if you've had any of these symptoms since you were last on site
• 10:00 - 10:30 even if you're now better or if a member of your household has experienced these symptoms the Occupational Health Team are available seven days a week between the hours of six in the morning and ten in the evening on the mobile phone number shown the Occupational Health team will decide whether you can come to work and what sort of work you can do If you experience these symptoms when
• 10:30 - 11:00 you are already at work please remove yourself from the production environment environment immediately and let your line manager know please also contact Occupational Health at the next available opportunity the plant quality team will decide whether whether there has been any risk to the product made one additional note when you see your GP please tell them that you work at a food
• 11:00 - 11:30 factory just a few other points about some medical issues all visitors need to complete a health questionnaire that should need to be signed off by the host before they come into the factory just another reminder about not carrying any medication into the factory unless Occupational Health have given you an exception if you've got a medical alert for some reason please continue to wear it but do
• 11:30 - 12:00 so underneath your garment it's really important that any Cuts or injuries on our hands are covered and it should only be covered with blue metal detectable plasters and it's also really important that if you've got a weeping cut or wound you must tell Occupational Health before you start work
• 12:00 - 12:30 so now we'll move on to the source of work where we should wear within the manufacturing area to start with please know that only Factory approved Workwear must be worn within the production environment and you can see here the Workwear that is provided their net should be worn which should cover your hair and your ears
• 12:30 - 13:00 you should also if you have facial hair wear a beard snood that should cover it the company also provide named body warmers and there is a long sleeve option available underneath that body warmer we provide a long sleeved white top some areas have short sleeve top tops if they are particularly hot environment
• 13:00 - 13:30 we also provide blue trousers and white shoes which are for inside use only if you need to go outside in your Factory White you should wear disposable overshoes and a disposable Overcoat and if you are not wearing Factory issued trousers you should wear a long lab style
• 13:30 - 14:00 Overcoat the requirements are very similar for technicians with the only differences being the technician trousers and tops are both blue and they are Cal rated technicians also have a black flame retardant body warmer
• 14:00 - 14:30 I'm just going to focus a little bit on hair do you know the average person loses about 25 to 50 hairs in one 12 hour shift if we don't catch these hairs it's possible they may fall in our products and the consumers will have the unpleasant experience of pulling one of your hairs out of their mouth so please remember to completely cover your hair with your hair net
• 14:30 - 15:00 you mustn't use pins or grips in the hair as well because they could fall into the product and it's our single yeast only and you must put them on first and you mustn't take your helmet off whilst you are wearing your white workwear you need to wear a beard snood if you've got any visual visible facial hair or if you've got sideburns that are
• 15:00 - 15:30 longer than the ear and please remember if you're wearing a hard hat or a bum cap for safety requirements you need to wear your hair net underneath it a few other points about workwear whether you enter the changing room you do so on the non-factory the yellow side of the changing room and that's where you remove your non-factory garments and
• 15:30 - 16:00 move to the green side where you put your Workwear on hair net first as we've said before most about garments now are long sleeved and it's just a reminder if you are working above product or product contact Services your arms must be covered when using the toilet cubicles Your Overcoat or your boiler suit if you're wearing one must be removed and hung up
• 16:00 - 16:30 toilet cleaners wear red Workwear to identify them hi this jacket should not be worn when working on a food production line hi this jackets are for stores and Logistics rolls foreign just a final reminder your factory a Workwear must be washed through the company laundry it must not be taken
• 16:30 - 17:00 home and washed we're just going to spend a few moments talking about gloves bournville site operates a no glove no touch policy because it's a very important way of preventing hand injuries however if gloves are not looked after correctly they can cause a foreign matter risk in our products you can see in the top left an example where a glove was lost and actually parts of it were found in one of our
• 17:00 - 17:30 machines and in the bottom right example of a glove that is very badly damaged and worn these sorts of issues can lead to Forum matter risks in our product or even microbial risk risks from Dirty gloves it's really important that you check the state of your gloves before you use them make sure that you dispose of any gloves that are damaged or too dirty to clean
• 17:30 - 18:00 if your gloves do get dirty and you can clean them with a sunny wipe then please do so it's also important to remember not to handle product or ingredients with these cut level safety gloves it's better to use sanitized hands or specially provided food contact gloves if you're going to touch the product if you do lose a glove please report it immediately to our inline lead online
• 18:00 - 18:30 lead so that any risk to the product can be assessed and to stop you losing your glove when you're not wearing them please put them safely in a pocket below your waistline or in your locker never ever leave gloves loose on the line or the equipment it's also important to change your gloves if you're moving to work in a different allergen area and it goes without saying but please
• 18:30 - 19:00 remove your gloves when you leave the manufacturing area or when using the toilet a couple of other points about workwear earplugs are an important piece of safety PPE but please make sure you've gotten securely attached in your ears and you don't lose them the ones provided by the business are metal detectable so please use these hard hats or bump hats are another piece
• 19:00 - 19:30 of safety PPE but please remember to keep them clean and store them in a high in a hygienic manner don't use your Bump hat or your hard hat to store other items like pens or tools this slide describes the standards in our Mix Design that is the area of the plant where you will have people in their whites and non-white garments and this applies to the the office areas
• 19:30 - 20:00 mainly around V2 so the v2a manufacturing office the other offices within linden2 the timeout Cafe itself and in addition the Linden 3 training area in all these areas it's acceptable to wear white but also non-white clothing but in these areas because there are people in white we need to set a much higher standard than the rest of the bourneville office
• 20:00 - 20:30 space there are to be no Staples used in these areas the areas have to be kept clean to set the standard for the rest of the factory we are not doing anything that contains peanuts or Sesame allergens that we do not have on site no glass or glass jars glass bottles glass cups Etc are to be brought into these areas it is acceptable to wear watches and jewelry in these in these office areas
• 20:30 - 21:00 however you must not wear them if you are in your whites and if you're eating or drinking in this area or the timeout Cafe and you spill food or drink on your white Workwear then please change your garments before returning to the production line if you need a disposable or a spare coat there are some found in the small changing area in the v2a office so just before we finish and have our first knowledge check
• 21:00 - 21:30 have a think about whether these pictures below are showing examples of people complying or not complying with our GMP practices and if you don't think they are why not well I hope that wasn't too hard and you managed to spot that all these people are not following our GMP rules in the first example you've got someone wearing their ID badge above waist height and not using a metal detectable holder
• 21:30 - 22:00 secondly we've we've got someone drinking in a production area which is not allowed and lastly we've got someone who isn't covering their facial hair we now move on to our second section of the training GMP Factory practices and we'll start with the basics cleaning and sanitation there's a number of reasons we need to keep the factory clean and hygienic and they're on the screen in front of
• 22:00 - 22:30 you who's responsible for doing that then well the simple answer is you we all are responsible we need to clean as we go there are of course cleaning schedules some of which are done by our facilities management partner some of which are done by Mondelez it's really important that these
• 22:30 - 23:00 cleaning schedules are documented and we carry out the cleaning against our Sops our standard operating procedures it's also important to report areas that you do not think are at the correct standard whether they visually do not look clean or whether there is an unusual odor that might indicate it is not clean when signing off cleans it's important
• 23:00 - 23:30 that the people that do that are authorized and trained documentation is needed for audit purposes for everything that is cleaned and just a reminder about disposable cloths and Scotch Brite the green scourers they should only be used once and then thrown away they shouldn't we should never use these sorts of cloths to clean food contact
• 23:30 - 24:00 and non-food contact use them once and throw them away we have some parts washes or dishwashers on site on the lines you can see on the screen it's very important that we look after these machines the basis you need to remember are to follow the operating procedure
• 24:00 - 24:30 that is displayed on all of the machines at the end of the shift there is a self-cleaning cycle and some checks to carry out and you record those checks on the laminated wipeable sheet on the front of the machine and it's really important not to clean any non-food contact equipment or Tools in these machines these machines are there to clean food contact tools and parts only
• 24:30 - 25:00 so let's then talk about tools there are a number of different colored tools for food contact blue orange or purple depending on the allergens you use on your line non-food contact tools are either green or yellow and these two types of tools are used to clean floors we must never stall different colored tools together
• 25:00 - 25:30 and with never put the food contact tools the blue orange or purple tools on the floor if we store tools they need to be stored clean and dry in the correct location just a couple of comments about some other tools in the bite size area we have these wire brushes for cleaning heater bars and packing equipment
• 25:30 - 26:00 this is the only place that they can be used they should be inspected regularly and disposed of and replaced if the bristles become loose we have some food contact metal scrapers that will either have a stainless handle like this one or ideally a colored handle indicating the allergen profile of the line it comes from we must inspect the scraper before we use it to make sure it's not damaged and it inspect the equipment and the scraper after cleaning to make sure no damage
• 26:00 - 26:30 has occurred if it does have a stainless handle and not a colored one then the stainless handle needs to be stamped or engraved with the line where this scraper belongs and one reminder that wooden tools are not allowed within the production area and please don't use damage tools and don't modify at all to make it better if you don't think it's fit for purpose please get the right tool for the right job but don't modify the one
• 26:30 - 27:00 you have we have some vacuum cleaners on site that are used on product contact surfaces for example on wrapping machines these vacuum cleaners must be labeled as product contact and it must keep any nozzles or fittings clean and keep them off the floor just like we do any other food contact tool we also need to be careful how we control knives and scissors on site we must only use company issued safety
• 27:00 - 27:30 knives and scissors and we've never used snap-off blade type a knife under any circumstances we need to make sure we inspect these safety knives and scissors before we use them must put them back in the correct storage location and never leave them loose lying around the plant technicians sometimes use safety night knife where we fit the blades spare blades must always be kept in the
• 27:30 - 28:00 workshop in a closed container these spare blades must never be taken in light onto the lines or in line side toolboxes it's very important when we do maintenance work on the plant that we do it hygienically and that if any work has been done on product contact surfaces or above
• 28:00 - 28:30 product contact surfaces we need to make sure we clean and sanitize and ensure that all tools and parts have been removed from the area before food manufacturer can continue to ensure we do this we have a handbag record a food safety and quality job completion sheet this document records that all the services have been cleaned and all tools and parts have been removed
• 28:30 - 29:00 it's completed by the technician or engineering contact contractor doing the job and it is counter-signed by a member of the production team who is receiving the equipment back so we continue the theme of talking about engineering Parts and Equipment it's really important that they are stored correctly so they don't pose a contamination risk sometimes we see on plan
• 29:00 - 29:30 engineering Parts left loose around workshops or near to the line side or even on pop-ups and lifters as you can see in the photo occasionally we see hoses that are not coiled back after they've been used it's really important to follow 5S standards and ensure when we are have finished a job things go back in the correct place engineering Parts should be stored in
• 29:30 - 30:00 green poly pans in the correct locations in workshops and storage areas we're going to talk now about tape and stickers these are our potential foreign matter or extraneous matter risk we must never use tape including PTFE tape and for putting on pipe threads above product contact surfaces
• 30:00 - 30:30 if we do use tape in anywhere on the plant away from product contact services it must be tidy and have any loose ends cut if it's being used as a temporary repair this must be logged by the technician as a temporary repair and a permanent repair made as soon as possible tape is not the only risk to of extraneous matter or for a matter on the
• 30:30 - 31:00 plant you can see a number of things that could potentially get in our products and cause discomfort to our consumers and damage our reputation so what can you do well it's a really good idea when you're on the plant to look up above product contact surfaces is there anything that could potentially fall off and land on those surfaces we also have processes like glass to have plastic records and mold and bucket
• 31:00 - 31:30 breakage records to ensure that when things get damaged they are recorded report anything you think is a risk to the product and hold product if you believe it is being contaminated thank you one potentially very serious source of contamination when it comes to chocolate is water leaks through the building infrastructure or from condensation if
• 31:30 - 32:00 they get into the ingredients packaging a product could cause a serious food safety risk if you do notice a water leak within the factory first thing is to think Safety First and restrict movement through the area the that if it has affected any material or packaging or product make sure that it's put on hold so it cannot be used if possible collect a sample of the water that has leaked and put it in the fridge on the V3 sample link Bridge
• 32:00 - 32:30 next thing is to get the issue fixed so the leak is no longer happening and then before and after it is cleaned up swabs can be taken and again left in the fridge on V3 to make sure we can properly assess the risk to the product it's very important in a food factory to
• 32:30 - 33:00 make sure that things go in the right containers on the screen you can see the different color coding we have for the different types of ingredient white is unwrapped food product unwrapped we rework blue is wrapped assortment's whip green is engineering parts red is byproduct so for example floor waste yellow is Creme Egg wrapped whip
• 33:00 - 33:30 and gray is slave trade reject rework from rappers please ensure as you're using containers you inspect it before it is used to ensure it's not damaged if it is damaged make sure any damage containers are scrapped and just a reminder if any product whether it is wrapped or unwrapped touches the floor it must be sent to a red byproduct waste bin
• 33:30 - 34:00 just take a moment to make sure you are aware of the different colors on the screen one important aspect of good manufacturing practice in a food factory is Pest Control we don't want pests to get into our products and affect our consumers and our reputation the sort of pests we need to be concerned about on bourneville site are shown on the screen
• 34:00 - 34:30 and what can you do to help with Pest Control well simply the four D's the first deny entry make sure external windows and doors are closed so pests cannot come in see any damage to the infrastructure that could allow a pest in please report it deny sources of food through good cleaning and sanitation and keeping waste covered make sure the rooms are organized so
• 34:30 - 35:00 denying hideouts denying shelter to the pests in the area and finally destruct The Last Resort by our Pest Control provider for example through the use of insects insecticides moving on to how we manage materials would you buy anything in a supermarket if it wasn't covered properly label and clean you wouldn't so those three
• 35:00 - 35:30 important things are what we need to consider when it comes to our materials and ingredients they need to be covered any food contact packaging material ingredients or rework should be covered the packaging should not be damaged if it is we shouldn't use it everything should be labeled so we know what it is and we know it's shelf life a packaging of our ingredients and packaging should be clean if it's not clean as in the photo there don't use it
• 35:30 - 36:00 ingredient containers even when they're empty should be kept clean and covered like our River bunkers on our tablet lines we should only use materials if they're within the manufacturer's expiry date to help prevent things going out of date we should use fifo first expired first out it goes without saying but we should never sit or stand on any materials or
• 36:00 - 36:30 Packaging and if we've got bulk materials like chocolate or caramel they should be kept with the lids shut and any open-ended pipe work for example on Hoyas should be kept clean and capped off when not in use we have a number of different plastic palette colors on site which you can see on the screen
• 36:30 - 37:00 material should always be kept on pallets and not put directly on the floor there should be a gap between the pallet and the wall ideally about 30 centimeters to allow cleaning and we should always make sure pallets are in good condition I never store materials or packaging directly onto pallets there should be a slip sheet or another cover between the wood and the material
• 37:00 - 37:30 wooden pallets must not be near used near exposed product and we never use them to store box food ingredients that are decanted by hand for example raisins where wooden pallets are used they should be in a good condition if you find a broken pallet ask your service person to move it to the broken pallet storage area which is outside opposite the main deck you see any bits of wood from a broken pallet on the plant sweep them up and
• 37:30 - 38:00 dispose of them as soon as you can we have a number of different colors of shrouds to differentiate different sorts of work the main color you need to be aware of is red a red shroud means the work is on hold and it should not be used with blue meth detectable shouts for rework and we use a variety of other colors for Whip and poly pans
• 38:00 - 38:30 some of our product can be sent in the white box as you can see on the screen to a company called sweet dreams this company uses it to make confectionery products that are suitable for human consumption so the product in these boxes is not waste as it clearly says on the side it should only be food grade material so never put floor waste or other things like wrap or wipes or Tools in these
• 38:30 - 39:00 boxes when these boxes have been filled they need to be shrouded the shrink wrap needs to be put around the boxes to seal the Shroud to the top of the box they need to be labeled the boxes need to be not overfilled or damaged only Creme Egg OPM 7 and line 5 can use these boxes no the line should have these white boxes on their line with a duty to maintain accurate records
• 39:00 - 39:30 to show that we are following all the relevant food safety Regulatory and quality rules if you make an error on a record paper record and you need to correct it please don't just cross it out and write the correction in as well as that you need to write your initials and the date that you made the correction these records may be needed to show our
• 39:30 - 40:00 legal or food safety compliance so please treat them with respect they deserve we need to be aware that we are certified at bornville for both kosher and Halal the flavor stores is certified to both these standards and chocolate making and some of our assortments tablets and countlines areas are certified to Halal standards this means in the main that alcohol and alcohol derived products are not allowed
• 40:00 - 40:30 in on these lines and the meat derived products especially from pork are not allowed in these lines as well and we ordered compliance with these standards regularly and if we follow the GMP guidance in this training we will comply with these standards we're now going to move on to talk about hassa HACCP Hazard analysis of critical control points it is a risk assessment tool to identify
• 40:30 - 41:00 the significant control points that will keep our consumers safe foreign ccp's critical control points or spps specific prerequisite programs bournville has no ccps but it does have a number of spps these spps are the points that we need
• 41:00 - 41:30 to control in order to maintain safe food if you are monitoring or verifying as a CCP or an spp then you need to be trained in order to do that one of the main food safety risks we all need to be aware of at bourneville are allergens the symptoms of anaphylaxis which comes
• 41:30 - 42:00 from a severe allergic reaction are shown on the screen both in the words and pictures and ultimately and sadly fatalities can result from anaphylaxis it's also responsible for most food recalls within the food industry so it's something we need to take extremely seriously these are the 14 main allergens have a look at them and think how many of those
• 42:00 - 42:30 do we have at bourneville site and whether you got that right but we have five wheat egg milk nuts and soya foreign as a food business we have an obligation under the law to make sure information
• 42:30 - 43:00 is provided about the allergens in our ingredients and products to our consumers and we need to make sure that no food is contaminated with an allergen that is not mentioned on the label what this means for us is that we need to ensure all the allergens on site hazelnuts almonds eggs and wheat are managed properly uh they don't contaminate products or areas where they
• 43:00 - 43:30 are not used and this includes controlling rework on site on some of our labels you'll notice it has may contain labeling for example this whole nut wrap says may contain other nuts and wheat however this does not mean it's acceptable to have these allergens present there should not be almonds another nut
• 43:30 - 44:00 or wheat in this product and we control this by doing something called an spp allergen Quality Clean between products we make sure we clean up allergens if they're spilled in the area we make sure we only add the same rework back into the into the product and we communicate and train people on allergen management one important thing to be aware of with
• 44:00 - 44:30 regard to Allergy management is tall colors we have orange tools for use in areas where we only have milk allergen present that would be chocolate making bite-sized areas the u4s cream plant the flavor stores U6 East and the euphorest extruder and the euphori sheeter down to the U2 East as well the cheetah area we have blue tools which
• 44:30 - 45:00 uh use scenarios that have nuts or egg which will be Creme Egg OPM three and four line five and six and V1 and V2 and purple Tools in areas where we have nuts and wheat present and that will be our OPM tablet lines one seven and our new line opm2 never ever take a tool from one line to another only use the tools that are designated the color for that line
• 45:00 - 45:30 it's really important if you noticed an allergen material has been spilled to follow the correct procedure this involves cordoning off the area to prevent cross-contamination and then cleaning up the floor using green floor contact cleaning if you're in production rooms or yellow floor contact tools in the stores then dispose of the waste into the red poly pans
• 45:30 - 46:00 and clean your tools and return them to the area where they are stored if the allergen that's spill is not in the profile for the area that it has been spilled in please inform the quality team as further action may be necessary to protect our consumers foreign and how we transport them different allergens can be delivered on the same trailer provided all the packaging and the pallets are in good
• 46:00 - 46:30 condition The Only Exception is whey powder which must be delivered to site on a trailer that is free from all other allergens and that's because this material ends up being used in chocolate making which is a milk only allergen area we now move on to our third and final and by far shortest section of the training looking at Food events food fraud and special situations
• 46:30 - 47:00 so what are food defense and food fraud they both refer to the deliberate contamination of food but for slightly different reasons food defense refers to contamination of food done by someone who is behaviorally or ideologically motivated this could be a terrorist organization a political pressure group or someone with a Criminal Intent
• 47:00 - 47:30 food fraud refers to deliberate contamination of food that is economically motivated it could be someone stealing our branded packaging in order to sell another product or one of our suppliers diluting their ingredients to sell us something that is cheaper so we have a food defense management system on site to reduce the risk to
• 47:30 - 48:00 site of deliberate contamination and we do that by restricting access to the site to only authorized individuals we control our perimeter through the Primitive fence CCTV and security Patrols we prevent personal possessions being brought onto the site by providing lockers for people in the changing rooms and we escalate any threats or risks through our special situations team so what can you do well the main thing
• 48:00 - 48:30 is to keep your eyes open and Report any suspicious activity if there are any unaccompanied visitors anyone who looks lost or someone you don't know taking photos or videos of your line someone who calls you out of the blue and tries to get information about the factory or someone who is trying to get in access to the site or if you see an unattended or unusual vehicle or an unintended bag on your line report it if you lose your security card please report it immediately to security
• 48:30 - 49:00 make sure that you cover food containers and store them in the correct location so they are not easily contaminated by somebody ensure chemicals are always locked away don't use materials that look like they've been tampered with for example the seals on a vehicle not being intact make sure any external points particularly tanker points and external doors make sure they are always locked when we are have completed a shipment and we are sending product out it needs
• 49:00 - 49:30 to be on a seal trailer and please make sure that any waste material that's Cadbury branded must be destroyed or it's not if it's about to be destroyed lock it securely in the specific cream Street store until it is destroyed foreign control is particularly important any non-food-grade chemical must be kept under locked conditions whether it be an
• 49:30 - 50:00 external building or whether it be in a technician's workshop it must be locked so in summary report any unusual behavior to your managers keep all your materials product packaging and chemical secure keep external windows and doors locked and once you've reported to your manager they will escalate through the special situations procedure so we keep mentioning special situations
• 50:00 - 50:30 what are they well a special situation is any unexpected or unpredictable event and you can see some pictures on the screen there that summarize some recent ones um that have happened within the food industry it's something that poses a risk to either people our products the environment our reputation our ability to operate the law or the assets of the factory if you become aware any of these events or any you are any potential event that
• 50:30 - 51:00 could lead to a significant issue like this then please let your manager or a member of the site leadership team know straight away the site leadership team will then escalate to the UK special situations management team if required