SUNDERLAND
SITE
INDUCTION
Duration 2.5 hours
Reference
Version No.
Date
Issued by
Authorised by
Sunderland Site Induction
27
22/07/15
Technical Coordinator
Technical Manager / HR Manager
Our vision:
£3billion sales by 2015
Market position
£4.0bn
£3.4bn
£2.6bn
£2.0bn
£2.0bn
£1.4bn
£1.0bn
£0.7bn
£0.3bn
Note:
1.
ABF revenues represent grocery segment only. Forecast growth CAGR based on consensus analyst estimates (Factset)
2.
Marfrig revenues for Western Europe as further granularity not available - core countries are UK, France and Germany
Current position
Brands and own label
No.4 UK food company
£2.1 billion sales
Our Recipe for Success:
One team, where everyone counts
Our Recipe for Success:
Our DNA:
Our purpose:
Highly competitive retail
market
Highly competitive retail
market
One team, where everyone counts
Price
comp
We buy for less, produce for less, sell more for less
Price
etition
comp
Our customers are at the heart of everything we do
Price
is
key
etition
comp
We relentlessly innovate to delight our consumers
Price
is
key
etition
comp
Every penny counts
Price
is
key
etition
comp
is
key
etition
Highest quality food at the lowest cost
Price
comp
etition
Our
ambition:
is key
To become a £3bn food company by 2015
Price
comp
etition
is key
Highly competitive retail
market
Highly competitive retail
market
Highly competitive retail
market
Highly competitive retail
market
Highly competitive retail
market
Highly competitive food
industry
Industry over capacity
Low barriers to entry
Highly competitive food
industry
Industry over capacity
Low barriers to entry
Highly competitive food
industry
High commodity inflation
Industry over capacity
Low barriers to entry
High commodity inflation
How we will succeed – the virtuous circle:
Milestones:
Highly competitive food
industry
High commodity inflation
Industry over capacity
Low barriers to entry
is key
Sales
Highly competitive food
industry
Industry over capacity
Low barriers to entry
Highly competitive food
industry
High commodity inflation
Industry over capacity
Low barriers to entry
Better value
£bn
Increased volumes
Highly competitive food
industry
High commodity inflation
Industry over capacity
Low barriers to entry
High commodity inflation
“Step
change”
High commodity inflation
Community
£3bn
“Fit for growth”
Selective acquisition
Organic growth
People
Customers
Operations
Finance
£2bn
“Quick wins”
2012
3
2015
Beyond
Lower cost production
Drives efficiency
Highest Quality – Lowest Cost
Our valued customers include:
Company background
• Founded in 1993 by our Chief Executive Ranjit Singh, the
company has evolved from a small scale frozen retail cutting
operation into a successful international food business.
• We have 35 manufacturing sites in the UK and Ireland, 6 in the
Holland and 1 in Poland, we employ around 18,000 employees
worldwide.
• We process over 6 million birds per week.
• We are the market leader in UK poultry and ready meals.
• Our Fox’s biscuits brand are currently number 2 in the biscuit
market.
• We are number 1 in the Christmas pudding market.
FOOD SAFETY, LEGALITY
& QUALITY
Food Safety Management
Food poisoning can be caused by poor hygiene and the
introduction of particular HAZARDS:
• Contamination by poor hygiene practices
• Food poisoning bacteria (pathogens)
• Chemicals e.g. cleaning chemicals, machine oil,
allergens
• Physical contaminants e.g. glass, sharp metal, stones
• Poor temperature control which causes pathogens to
multiply
• Undercooking which causes pathogens to survive
HACCP
Hazard Analysis (HA)
HACCP is a system which looks at every process step in the factory and
assess the possible hazards at that step, and what controls are needed
to reduce the hazard.
Assessment is made as to how critical the hazard could become.
Critical Control Points (CCP)
These are process steps that have been identified as critical to food
safety.
CCP 1.0
Raw Material Intake
CCP 1.1
Chill
CCP 2
Cook
CCP 4
Metal Detection
HACCP
In its simplest form, HACCP involves:
•Identifying food safety hazards - i.e. those things in the process that
would make the food produced unsafe to eat
•Controlling those hazards – especially at those points critical to food
safety
•Monitoring the controls – checking the controls are in place and that they
are working
•Corrective Action – the action taken when monitoring indicates that a
control isn’t working. This involves rectifying the problem that resulted in
the control failing and dealing with the product that was produced when
the process was out of control
•Documentation – recording details of the process including the
monitoring and the corrective action
Tier A – General Understanding of Metal
Contaminants and Detection
Reason for inspecting products
Food Safety
We all have a responsibility to protect the consumer
What do we do to prevent Metal
Contamination
•
Metal Detector on every production line
•
Inspect every product
•
Treat the Metal Detector as a Critical Control Point (CCP)
•
Isolate potential contaminated packs and investigate
thoroughly
•
Test the Metal Detector at regular intervals
General understanding of metal contaminants
What are we trying to detect
Many contaminants found in product will come
from the equipment and machinery producing the
product.
Such as:
Nuts, Bolts & Washers
Bits of Cutting Blades
Steel Shavings
Wire etc. etc.
Other metal contaminants are sometimes already
present in product. ( Poultry, Beef Tongue etc.)
Detection of Contaminants
What a Metal Detector cannot detect
–
–
–
–
Glass
Stones, Ceramic and Cement
Bones
PVC & TFE
• Packaging materials or belting
material is not detectable
– Natural Rubber
General understanding of metal contaminants
Types of Metals
It is generally understood that there are 2 types of metal
classification


Ferrous
Non-ferrous
However within the food industry 3 classifications are used



Ferrous
Non-ferrous
Stainless Steel (Non Ferrous Family)
What is expected of anyone coming
in contact with a metal detector
Do
•
Maintain good Housekeeping.
•
Adhere to processes and practices as detailed in company
procedures.
•
Notify supervisor if you see anything you think could be a problem.
Damage to the MD system including safety devices.
People not following processes
•
Always respect the MD system when a reject action occurs
What is expected of anyone coming
in contact with a metal detector
Don’t
•
Bypass any processes detailed in company procedures.
•
Bypass any system fail-safes.
•
Remove rejected products from reject bins unless authorised.
•
Interfere with the normal operation of the MD system.
•
Alter the MD system settings unless you have the authority to do so.
•
Use the detector system as a shelf.
Metal Detector – Questions
Low & High Risk
The HACCP risk assessment has identified that the site needs
three different food handling areas:
•Low Risk – where raw meats are handled, which are subject to
cooking
•High Risk – where cooked product is directly handled
•Packing & Transport – where sealed finished product is handled
Smoking
Area
Site Plan
Raw Material & PPE Store
Waste Skip
Goods-In
T6
T5
CAR
PARK
LOW RISK
Concrete Yard
T7
HIGH RISK
Tumbling
Despatch (Enclosed Product
Area)
Raw Material Chill
T4
T3
Dry
Ingredients
Store
T2
T1
Dicer
Injector
Osmosis
Chill
Temper
Unit
Raw Material Chill
Rack
Chill
Grader
Low Risk Process
Room
Truss
Bone Belt / Grader
Train-ing
Room
LR Changing
Room
Small
Roast
Toilets
Plant Room
Rack Wash
Despatch
Changing Room
Tray wash
Steam
Ovens
Oven
Unloading
Belt Grill
Searer
Oven Loading / Racking Up Area
Toilet
Large
Roast
Dicer
San Spray
Shredder
Turbovac
Packaging Store
Dicer
Multivac
N2 Tunnel 3
Slicers
N2 Tunnel 4
Finished Goods Freezer
BC 1BC 2
N2 Tunnel 5
Canteen
Toilets
Reception
HR Changing
Room
POD Blast Chill
POD WIP
Finished Goods Chill
Allergen Control
Allergens are substances, usually proteins, which cause the body’s
immune system to respond. In severe cases this may result in an
anaphylactic shock and even death.
Symptoms include:
• Generalised flushing of
the skin
• Nettle Rash
• Swelling of the throat and • Difficulty in swallowing
mouth
and speaking
• Severe asthma
• Abdominal pain, nausea
and / or vomiting
• Sudden feeling of
weakness
• Collapse and
unconsciousness
Allergen Control
Failure to control allergens may result in an allergic reaction.
Allergen Control
Common allergens include:
• Peanuts
•Tree Nuts
•Milk
•Cereals containing gluten
•Fish, Shellfish & Molluscs
•Celery / Celeriac
•Soya
•Sesame Seeds
•Mustard
•Eggs
•Lupin
•Sulphites
Sunderland site uses ingredients which containing allergens highlighted in red.
We are a nut and sesame free site.
This includes:
• Products produced in the factory
• Products in food brought to site by staff (remember
McDonalds has sesame seeds on the bun)
• Make-up and cosmetics used on site (check the label)
Allergen Control
It is very important that the production process controls allergens so that they do
not contaminate product that does not contain the allergen.
Control measures we use to reduce the risk of allergens:
• When raw materials arrive on site the packaging is to be intact, no spillages
to be present in the vehicle and are to be from a supplier on our approved
supplier list
• While we store raw materials, the ones containing allergens are to be in
defined areas and clearly labelled
• We decant raw materials that contain allergens after those that do not
contain allergens
• For powders, the tub we store the powders in has a scoop chained to the
tub so the scoops can’t get muddled
Allergen Control
The production plan is set up to ensure allergens are only used in a certain order and
after products which don't contain any allergens
Example: Low Risk Tumbler 1 has just tumbled a mustard product what can you
tumble next?
Brine only (No allergens)
Milk Marinade
Mustard marinade
Mustard Marinade
Wheat & Mustard
Marinade
Allergen Control
• Wash hands after handling allergens.
• Sieve allergens with the sieve turned off in static mode to prevent a lot of
dust
• A Pink Tag identifies all tumblers, dolavs, racks and trays containing
products containing allergens
• A Pink Tag from the introduction of the allergen in the marinade the tag
remains with the product until packed into bags.
• Allergy signs are located in key areas including the ingredient storage
areas, Low Risk and High Risk. These signs explain which ingredients and
finished products contain allergens.
Allergen Control
ALLERGEN POSTER FOR INGREDIENTS
Allergen Control
ALLERGEN POSTER FOR FINISHED PRODUCTS
HYGIENE
Hand Hygiene
Why should we wash our hands?
To remove dirt and bacteria
When should we wash our hands?
When entering and exiting production
areas
Minimum every 2 hours in High Risk
Before touching any food
After handling raw food
After visiting the toilet
After sneezing or coughing
After touching your hair or face
After cleaning or touching chemicals
After handling rubbish
After eating, drinking or smoking
Hand Hygiene
Drying:
Drying is just as important as soap application. Studies have shown 1000 times more bacteria is
spread by wet hands than dry hands.
Sanitise:
Contains alcohol and a biocide which kills any remaining bacteria on the skin’s surface.
Hand Hygiene
Commonly missed areas during hand washing:
Gloves
Hands must be washed prior to the use of gloves.
Gloves must be changed:
•After coughing or sneezing on gloves,
•Following handling unsuitable materials,
•Every 2 hours or change over of product; whichever is sooner
•If damaged
Try to check gloves every 15 minutes for damage.
Stop handling product and inform your Team Leader if you notice any
damage so product contamination can be minimised.
Personal Hygiene
Nails:
Must be kept short and clean, no nail varnish, no false nails. Nails are too long if they are
visible from the palm side of the hand or when viewed with the tips of the fingers level with the
eyes of the viewer.
JUST RIGHT
Make-up and scents:
No excessive aftershave, perfume or facial make-up.
No false eye lashes.
TOO LONG
Personal Protective Equipment
PPE is colour coded: It must be worn without failure.
Low Risk
High Risk
Cleaners
Allergens
Gloves
Sleeves
Aprons
Hair
Nets
Mop Caps
Red
Blue
Yellow*
Green
Red
Blue
Yellow
Green
Red
Blue
Yellow
Green
Red
Blue
Area
Area
Red
Blue
Area
Area
When directed or trained to do so additional
PPE may be required, e.g. eye protection or
ear defenders.
PPE must be worn for your own protection against possible risk to health.
Changing Procedure
Low Risk
High Risk
•Blue Coat
•White Coat
•Red Hair net (1ST)
•Blue Hair net (1ST)
•Green Boots
•White Boots
•Mop Cap (2ND)
•Mop Cap (2ND)
•Snood (if
required)
•Snood (if
required)
•Additional PPE if
required
•Additional PPE if
required
Low Risk Changing
Procedure - Entry
2
3
Wear a
hairnet &
mopcap –
over both
ears
If required,
cover facial
hair with
snood
Sit and
swivel
over
bench
5
6
7
8
Select
boots
from rack
and wear
Wash
hands &
dry
Remove
blue coat
from bag
and wear
1
Remove
outdoor
footwear and
place in rack
Wear red
feet covers
(optional)
4
Sanitise hands
Low Risk Changing
Procedure - Exit
1
2
3
Remove blue
coat & hang on
hooks
Remove
boots
and
place on
rack
Wash
hands
& dry
4
5
6
Sanitise
hands
Sit and
swivel over
bench
Dispose of
hair net and
feet covers in
bin.
If soiled put into
chute
Red coats to be
hung on red
hooks
High Risk Changing
Procedure - Entry
1
2
3
4
Remove
outdoor
footwear
and place
in rack
Wear a
hairnet and
mopcap –
over both
ears
Sit and
swivel
over
bench
Select
boots from
rack and
wear
Wear blue
feet covers
(optional)
If required,
cover facial
hair with
snood
5
6
7
8
Wash hands
& dry
Remove
white
coat from
bag and
wear
Wash
hands &
dry
Sanitise
hands
High Risk Changing
Procedure - Exit
1
3
Wash boots
in boot wash
5
Remove
boots
and place
on rack
Dispose
of hair net
and feet
covers in
bin.
2
Remove
white coat
& hang on
hooks
If soiled
put into
chute
Green
coats to be
hung on
green
hooks
4
Sit and
swivel
over
barrier
Removal of PPE
When leaving production all PPE must be removed in reverse order.
• All coats must be placed in the laundry basket.
• Hats, hairnets and snoods must be disposed of.
• Wellington boots must be stored on the racks provided in the wash
room. They must not be left on the floor.
Pockets
Only the following can be taken into the factory in your pocket:
Locker Key
Critical Medicine (with authorisation)
Factory Phone (Management Only)
Factory Radio (Management Only)
The following should not be taken into the production areas:
Cameras
CD / MP3 Players
Personal Mobile Phones
General Medication
Food
Car Keys
Coins
Pens
Smoking equipment
Chewing gum
Jewellery
The HACCP process has identified jewellery as a potential physical hazard.
Therefore, none of the following is authorised in any production area:• Wrist watches
• Visual body piercing
• Earrings
• Necklaces or bracelets
• Embellished clothes e.g. jewelled/sequined jeans
• False eyelashes or nails.
The following is permitted in the production environment with authorisation:-
Plain wedding bands with NO stones or engravings.
Religious jewellery or medical bracelet.
Pen Policy
2SFG – Sunderland Site have designated factory pens.
These should be used at all times when in the factory.
Blue casing only.
The pens are designed to be:
•Robust and shatterproof
•Colour to as a contrast against the product
•Minimum number of parts
•Metal detectable.
Pens with tops, springs or any other visible fixtures are forbidden
in the factory.
Your manager will issue pens if and when required.
Food, Drink & Smoking
Food & Drink
•The canteen is provided for the consumption of food. Food is ONLY to be
consumed in this area.
• Food is not to be stored in lockers; only in canteen area.
• No food is to be taken into the factory, changing rooms, toilets or smoker’s cabin.
•Food is not to be consumed when walking around external site areas.
Smoking
•Smoking permitted in smoking area only (main gate)
•No smoking in your vehicle when in the car park.
Breech of policy is subject to disciplinary action.
Product on Floor
Operatives must not:
• Touch the floor
• Pick anything off the floor
• Handle floor cleaning equipment
Only hygiene team are to handle product or raw materials that have
touched the floor.
Product and raw materials that has touched the floor are not to be used in
finished product and are to be disposed of.
Cuts & Grazes
All cuts and grazes need to be covered with a blue metal detectable plaster.
•Standard plasters must be changed to blue plasters before entering the factory.
•Blue plasters are only to be issued by approved first aiders.
•Any plasters issued are logged on the plaster log book.
•If a blue plaster is lost you must inform your supervisor as soon as your realise the
plaster has gone missing.
Knives
Only operatives who require knives will be given them.
The following rules are important with factory issued knives:
• These must be signed out and signed back in with the Section Team
Leader / Supervisor
•Only factory issued knives are to be used
•The knife must be stored in a location where it:
•Is not going to be easily lost
•Is not going to be contaminated / get dirty
•Not in your own pocket.
Glass Policy
Glass and rigid plastic items are minimised and wherever possible eliminated from
production areas.
Where this is not possible, glass and hard plastic items are:
• Protected in order to minimise the risk of damage
e.g. light fittings are shatterproof tubes
• Inspected on a frequency based on a risk assessment.
It is every employee’s responsibility to be aware of the danger of contamination to
the product from damaged glass/rigid plastic items, and to behave in such a
manner as to reduce the risk of damage to fixtures and fittings.
If you wear contact lenses or glasses you must inform your section team
leader immediately should they become lost or broken at any time on site.
Glass Policy
• Due to contamination potential, glass food and drinks containers
(including Thermos type flasks) should not be brought onto the factory
site.
• Any exceptions should be approved in writing by the responsible senior
factory manager.
Glass Breakage
• A glass breakage refers to a breakage of any glass or
glass like materials
STOP production-related activities immediately
Everyone to stop moving to prevent the spread of any
glass fragments
Technical department to be contacted by phone or
mobile if out of core hours
The area within at least a 10m radius will be isolated
(Production areas including external store)
Glass Breakage
No product, materials, equipment or personnel are allowed to
leave or enter the isolated area at this stage
People may only leave or enter the area if authorised by
Technical Manager, Technical Coordinator or QA Manager
An appropriate manager will inspect the isolated area fully
prior to restarting
Pest Control
Pests carry harmful bacteria on their bodies and in their urine and faeces.
Common pests encountered are:
• Rats
• Mice
• Moths
•Crawling insects
• Flies
• Bees
• Birds
• Feral Cats
External doors should be kept closed at all times.
Any sightings or evidence (e.g. droppings) from pests should be reported to
your Section Team Leader.
Occupational
Health
Health Services
When completing your starter pack you will also complete a health screening
questionnaire. This ensures the company complies with employment, health and
safety and food safety legislation.
At the end of the induction you will complete a Colour Blindness assessment.
Within 1 month of employment you will be required to attend an initial occupational
health appointment. This may include audiometric (hearing) and spirometry (lung
function) testing depending on the area you work in and the tasks you carry out.
None of the above assessments will have any bearing on your employment.
The Company reserves the right to require you at any time during your employment
to undergo a medical examination, including during long term absence or persistent
short term absences. The results of which will be disclosed to the company.
The purpose of which be to determine if may impair your ability to perform your
duties or which could assist your return to work. We may review the effect of your
continued employment on the basis of such medical evidence.
Sickness / Infections
Employees who have suffered from sickness and diarrhoea during the previous 7 days may only return
to work if they have been free from sickness and bowel disorders for 48 hours and have not taken any
medication to suppress symptoms. Should you suffer from any occasions of sickness or diarrhoea
during your breaks you must not re enter the factory and you must inform your Line Manager or
another member of the management team if your manager is not available before leaving site.
Employees who have an infection of skin, ears, nose, throat and eyes, are not to return to work unless
they have been authorised by a doctor.
Employees who have a cold, cough, sinus infection or fever will be assessed based on severity:
Light cold / cough – entry in a non-food handling role
Heavy Cold or cough – no entry to the factory unless authorised by a doctor
Employees who have shared household facilities with anyone suffering from Enteric Fever (Typhoid,
Paratyphoid), VTEC E-Coli infection, Dysentery or Norovirus during the previous 21 days are not to
return to work unless authorised by a Doctor. This will involve stool sampling.
Employees who have suffered from Enteric Fever (Typhoid, Paratyphoid), Cholera, VTEC E-Coli
infection, Dysentery, Hepatitis A are not to return to work unless authorised by a Doctor. This will
involve stool sampling.
Bodily Fluids
If at any time while in the production area you suffer from any of the following bodily
fluid spillages ask a colleague to inform a section team leader immediately:
• Vomit
• Blood
• Urine
• Faeces
It is important that you do not move around the production area after bodily fluid
spillages to prevent a contamination of a larger area.
Spitting is strictly prohibited on site.
Personnel must not cough or sneeze over materials or products and must wash
hands after coughing and sneezing.
First Aiders 0600-1400
First Aiders 1400-2200
First Aiders 2200-0600
First Aiders Offices Laundry
& Engineering
First Aiders
• On the shop floor first aiders are
identifiable by a yellow hair net.
Personal Medicines
All staff that require personal medicines to be brought onto site must inform
their supervisor or the HR department.
If it is not necessary for the medicine to be carried by the employee at all
times the medicine must not be taken into the production areas and be
stored with other personal possessions.
If the medication must be immediately available, for example without which
would cause serious consequences to a person’s health, the employee’s
medication may be carried with authorisation. The employee is responsible
for ensuring the contents are maintained at all times.
If the medicine goes missing, the employee must report this to
their Section Team Leader / Supervisor immediately.
HEALTH
&
SAFETY
Health & Safety Policy
Our policy is to provide and maintain safe and healthy work conditions, equipment
and systems of work for all our employees and anyone who may be affected by our
undertakings, and to provide such information, training and supervision as they
needs to be able to undertake the job safely, with out risk to health.
Legal Obligations
Health and Safety at Work Act 1974
• It is the duty of every employee to take reasonable care of their health and
safety.
• It is the duty of every employee whilst at work to co-operate with his employer.
• No person shall intentionally or recklessly interfere with or misuse anything
provided in the interest oh health, safety or welfare.
We are all equally responsible for the health and safety of each other.
Health & Safety Policy
Risk Assessment
• All tasks onsite have been risk assessed.
• Before undertaking any new tasks ensure you have read
and understood the risk assessment & the safe system
of work for the task.
Fire Awareness
Fire prevention is everyone’s responsibility.
•
•
•
•
Ensure you understand and follow fire procedure
Familiarise yourself with the fire instructions of the site.
Make sure you know the location of all fire exits, escape routes and assembly points.
Anyone who deliberately breaks the fire regulations will be dismissed.
•
•
•
Fire Alarm Test
•
•
•
•
Fire alarms are tested every Tuesday morning at 10.00am. A tannoy announcement will be made
prior to this stating that the alarms are to be tested and not to evacuate.
All other routine testing of fire alarms will also be announced, prior to this testing stating that this is
not an evacuation.
Any alarm that is not announced as a test must be treated as an emergency and all personnel
must evacuate and a role call must be taken to ensure all personnel are accounted for. The Fire
Marshall or Senior fire office will be the only persons to give the authority to return to work, if safe
to do so.
Fire Awareness
•
•
•
•
•
Point 1 – Head count to be undertaken by Receptionist
Office Staff
Visitors
Contractors
Engineers
•
•
•
•
•
Point 2 – Head count to be undertaken by Head Team Leader
Low Care Employees
Despatch Employees
Yard Employees
Goods In Employees
•
•
Point 3 – Head count to be undertaken by Head Team Leader
High Care Employees
•
•
Point 4 – Head count to be undertaken by Agency Representative
Agency Staff
Evacuation Procedure
Evacuation Procedure
•
•
•
If you discover a fire
Sound the alarm at the nearest point.
Immediately leave the building by the nearest exit.
You hear the alarm
• Stop work and turn off machinery.
• Immediately leave the building by the nearest exit.
• Report to your assembly point.
• Do not re enter until you are told to do so.
Do not
• Stop to collect personal belongings.
• Change PPE
• Re enter the building until authorised to do so.
• Panic or Run
FIRE EXITS AND ESCAPE ROUTES MUST BE KEPT CLEAR AT ALL TIMES
Failure to do so may result in disciplinary action.
Site Map
Accidents
If at any time while on site you have an accident it must be
reported to your Line Manager during that shift. They will
arrange for a First Aider to tend you, treat your symptoms and
make and entry in the first aid book.
If you fail to follow this procedure it may affect any entitlement
to accident pay.
Every accident and incident will be investigated by the Line
Manager to find the root cause, you may be required to assist
in the accident investigation procedure. It is your duty to cooperate in any accident or incident investigation.
Safety Concerns
Near Miss and Safety Concern Reporting Pads
• Please use to pad provided to record any Health and Safety
concerns you have.
• Once complete please place in the post box on the wall
This box will be emptied daily and all concerns investigated –
Situated in the canteen
Site Hazards
You should always
• Use the identified walkways
• Check for moving equipment such as fork lift trucks
• Watch where you walk for spills, debris etc
• High Visibility must be worn anywhere in the yard
Racks and Trolleys
• Always visually inspect general maintenance before use i.e. are wheels in good working
order.
• Always push the racks never pull.
• Look in the direction of travel
• Seek assistance if it is difficult to move or your vision is obscured.
Machinery
• Never operate any machinery you have not been trained to use and always operate in
accordance with safe working procedure.
• If a problem develops, use the emergency stop button to switch it off.
• Never insert any part of your body into moving machinery.
• Equipment must not be left running unattended
• Only engineers or maintenance operatives are permitted to undertake repairs
• Never remove or tamper with the safeguards whilst equipment is switched on and if not
trained to do so for cleaning operations
Noise
•
•
Following a noise monitoring survey in 2015 the high risk area and low risk rack wash area require all
employees and visitors to wear hearing protection, disposable and re-useable ear plugs are available at
the changing area and must be worn for the duration of your shift.
The Noise at Work Regulations 2005 requires by law employers to prevent risks to health and
safety from noise at work. It also requires employees to wear and look after the protection provided
by employer.
•
It is advisable to keep the ear plugs in the re-sealable bag when not in use, after use
•
•
•
•
Fill a bowl with warm water and soap, leave the ear plugs in there for a few minutes to soak.
With your fingers or if you prefer a tooth brush, remove all dirt and ear wax from the plug.
Leave to air dry, to discourage any bacteria, then store in plastic pouch.
Plugs can last 3-4 weeks, when looked after.
•
Ear plugs must be inserted into ears before entering food production areas and before final hand wash.
•
Once in place do not handle until you have left the process area. If you do touch or handle our earplugs
you must wash your hands thoroughly and change your gloves.
Signage
Prohibition Sign
‘DO NOT’
• Always red.
• Required by
law to comply.
Mandatory Sign
‘MUST DO’
• Always blue.
• Action required to
comply with
safety standards.
• Required by law.
Warning Sign
• Indication of danger.
• Required to undertake
reasonable safety
precautions,
depending on
information given.
Safe Condition Sign
• Provides you with
information on safety.
• May include fire exits
or first aiders
Manual Handling
Manual Handling Video
Available at S:\Sunderland Filestore\H&S\Videos
Chemicals
•
There are several potentially hazardous chemicals used on site:
– Cleaning chemicals
– Product test chemicals
– Engineering chemicals.
•
Other than hand wash chemicals and boot wash chemicals, do not touch any chemical or
chemical container, unless you have been trained fully on chemical safety awareness.
•
If you are fully trained to use chemicals you must wear the correct PPE as specified in the
cleaning instruction cards and risk assessment.
•
If you see any of the following report this to your supervisor:
– Chemicals with no labels
– Chemicals that are not locked (in situ on in cupboards)
– Any chemical spillages
– Any misuse of chemicals
•
Chemicals will harm if misused.
Site Security
Staff, contractors and visitors shall be trained in site security procedures.
•
All staff, contractors and visitors are to enter the site through the main gate at entrance to
site.
•
For your safety and site security we have trained security guards 24/7 365 days a year.
•
During out of operational hours (overnight and weekends) the main gate is locked. Access
can be authorised by the security.
•
CCTV is provided across the site, this is installed for your own safety.
•
Report to your Section Team Leader or Manager any unidentified or unknown visitors. All
visitors will carry a visitor badge and be accompanied by a 2SFG manager.
•
Report any strange behaviour of employees who could be attempting to contaminate the
product with hazardous materials.
•
All staff are issued with photo ID. Carry this with you at all times when not on the factory
floor and show if asked by security or by a Manager.
Site Security
Staff, contractors and visitors shall be trained in site security procedures.
•
All staff, contractors and visitors are to enter the site through the main gate at entrance to
site.
•
For your safety and site security we have trained security guards 24/7 365 days a year.
•
During out of operational hours (overnight and weekends) the main gate is locked. Access
can be authorised by the security.
•
CCTV is provided across the site, this is installed for your own safety.
•
Report to your Section Team Leader or Manager any unidentified or unknown visitors. All
visitors will carry a visitor badge and be accompanied by a 2SFG manager.
•
Report any strange behaviour of employees who could be attempting to contaminate the
product with hazardous materials.
•
All staff are issued with photo ID. Carry this with you at all times when not on the factory
floor and show if asked by security or by a Manager.
HR
Our Code of Behaviour
This code of behaviour is applicable to all our employees irrespective of their
position within it.
•
•
•
•
•
•
•
•
•
We will always try and adopt a collaborative working culture.
We will not seek to blame others but will work with each other to resolve any
issues or problems.
Saying ‘please’ and ‘thank you’ should be common place.
We will know the names of our immediate manager and other senior
management and managers should know the names of their direct reports.
We will be courteous and respectful to each other at all times.
Any issue raised by an employee will be seen as important and will be dealt with
promptly by the person best placed to resolve the issue.
We will take an active interest in our own and each others welfare and the
morale of our teams.
We will treat others as we wish to be treated.
We will give no preferential treatment to employees based on family or long
term relationships. Employee performance, experience and possession of the
relevant skill sets, will be the criteria.
Full details of all policies and procedures are available in the employee
handbook.
Equal Opportunities
We are committed to an active equal opportunity policy, from recruitment and
selection, through training and development, appraisals and promotion, right up to
retirement.
It is our policy to promote an environment free from discrimination, harassment and
victimisation where everyone will receive equal treatment regardless of:
Age
Marital or Civil partner status
Gender
Gender Assignment
Religion or belief
Hour of work
Disability
Political Opinions
Sexual Orientation
Colour
Nationality
Ethnic or National Origin
Race
Disfigurement
All decision relating to employment practise will be objective, free from bias, and
based solely on work criteria and individual merit. In every set of circumstances we
aim to find the ‘best fit’ between personal requirements and business needs.
Ethical Policy
Our Standards
1. Promote permanent employment wherever possible and adopt a planned approach to the use
of agency workers.
2. Recruitment practices protect workers and ensure fair, consistent and equal treatment such
that there is no discrimination in recruitment, pay or promotion decisions based on race, caste,
national origin, religion, age, disability, gender, marital status, sexual orientation, union
membership or political affiliation. We do not use and will not recruit child labour.
3. To ensure equal access to jobs and equal pay for work of equal value and that pay for the
standard contractual week at least meets the National Minimum Wage. Overtime is paid at a
premium rate.
4. To provide all workers with a decent standard of equipment and facilities whilst at work and
ensure that their working conditions are safe and hygienic.
5. Working hours will not be excessive; the maximum working week will be 60 hours. Overtime is
voluntary and workers will not be required to regularly work in excess of 48 hours per week.
6. To give all workers the opportunity to raise concerns and get resolutions by either following
the Company’s Grievance Procedure or by using ‘Speak Up’, our confidential multilingual
reporting line.
7. No harsh or inhumane treatment is allowed. Actual or threatened physical abuse or discipline,
sexual or other harassment, or verbal abuse or any other form of intimidation or bullying are
expressly prohibited and regarded as gross misconduct under the Company’s Disciplinary
Policy.
Tackling Hidden Exploitation
Recent figures show there are 30 million global victims of slavery, with a number of these cases a
lot closer to home than you may think. Human trafficking is the fastest growing criminal industry in
the world and is second only to drugs as the most profitable criminal industry. Exploitation can
consist of human trafficking, forced labour, rogue-landlords and work-finding fees, with some key
indicators that you can look out for to stay vigilant in protecting your site
Key Information
1. Be vigilant! You know when something doesn’t look or feel right.
2. Work together. If you suspect anything untoward, speak to
HR immediately.
3. Keep a lookout. You are the eyes and ears of everyone who enters
and exits our sites, as well as being able to monitor what activity is going on outside of our
gates.
What it might look like
•
Individuals being ordered into or out of a vehicle, when people are being dropped off or picked
up from work.
•
Have you ever seen food being distributed to an individual or group, outside of the canteen
area?
Don’t let this happen at our site !
Stronger Together
• Show video
Working Time Directive
Working hours will not be excessive; the maximum working week will be 60 hours
and workers will not be required to regularly work in excess of 48 hours per week.
Workers can agree to work longer than the 48 hour limit, by opt out agreement, this
must be in writing and signed.
You have a right to a day off each week, or 2 days off in 14.
You have a right to 11 consecutive hours rest in any 24 hour period.
You must not work more than 11 hours per shift, including overtime.
You have the right to a 20 minute break when the working day is longer than 6
hours.
You are entitled to a minimum of 28 days holiday per year. Some of which must be
taken on days confirmed by the company as stated in your contract. The company
does not recognise public holidays.
Night shift must not work more than 8 hours per shift.
Lockers
The following items are permitted to be keep in your locker:
Personal items
Outdoor clothing
Non prescription and/ or authorised medicines (by HR)
The following items are not permitted to be kept in your locker:
PPE (coats, aprons, gloves, boots, hairnets etc)
Factory paperwork
Food / drink
Glass/ ceramic items
Knives
Any items that deliberately block visibility into the locker
Random locker searches are carried out regularly and HR, accompanied
by a witness, will remove non-permitted items from lockers.
Absence Policy
• Absence must be reported personally on the first day via the absence reporting line 0191 521 9777, at least
one hour before the start of your shift. You must confirm your name, illness and likely length of absence.
• Throughout absence you must keep the business informed on a regular basis of your condition and likely date
of return.
• Absence due to sickness, injury or accidents for 7 days or less (including weekends) will require a selfcertificate form.
• Absence for more than 7 days (including weekends) to be covered by a medical certificate, from a UK based
practitioner.
• Medical certificates must be continuous to cover any absence.
Sick Pay
You are entitled to Statutory Sick Payment (SSP) of £87.55 per week if you are too ill to work, up to a maximum
of 28 weeks. To qualify you must:
Be classed as an employee
Tell us you’re sick 1 hour prior to your start time
Have been ill for at least 4 days in row
It is not paid for the first 3 days of your absence
Earn at least £111 (before tax) per week
Payment will be made in the same way as normal wages with the deduction of tax and national insurance.
Return to work
On your return your Team Leader/Line Manager will complete a 'Return to Work'
form and conduct a return to work interview. This must be completed before
entering the factory.
The form must be completed following:
•Any illness, at any time, including weekends and bank holidays.
•Following any absence outside of your normal working pattern.
•Return from any foreign holidays.
•Any agency staff that have been away from the business for more than 5
consecutive days.
•Any excessive occasions of sickness/unauthorised absence will be managed
through the disciplinary procedure i.e. 3 occasions in a 12 month period.
Holiday Entitlement
Holiday year runs from 1st January to 31st December and your entitlement is
stipulated in your contract. They must all be taken within this time period and approved
by your Manager.
Entitlement is pro rata for part time employees and those with less than 1 year service.
Your entitlement is calculated based on the number of weeks worked in a year.
Calculation example; for a full time new employee starting on the 16/02/2015 with an
entitlement of 28 days
Annual
Entitlement
Number of
weeks in
Year
28
X
52
Number of
weeks
worked in
Year
46
= 25 Days
entitlement
for the year
Contract Additional Information
Any overtime is freely chosen and will be paid at x1.25 your normally hourly rate.
Hourly rate is in line with or above legislation at £6.50 per hour, payable by credit
transfer, at a 4 weekly pay frequency direct into your bank account.
Nightshift receive an allowance of £6.31 per shift.
You must clock in and out for breaks and the beginning and end of every shift.
Next Steps
• Occupational Health visit within 1 month.
• Colour Blind assessment.
• Basic Food Hygiene course to be completed within 3 months. Start training plan.
• Issue starter pack, including contract, pre medical screening, bank details.
• Issue with clock card.
• All staff enter site via security entrance and must sign in and out. This is subject to
disciplinary action if not followed.
•Be issued with correct PPE by your Line Manager.
•Read, understand and sign all relevant risk assessments and safe systems of work
for the tasks you are carrying out.
Any issues, please speak to your Manager or contact the HR department for more
details.