Jul
19
2010
0

BRC Global Standards for companies in the Food Sector

In 1998 the British Retail Consortium (BRC) developed and introduced the BRC technical standard and protocol for companies supplying retailer branded products, namely:

  • BRC Global Standard for Food Safety. This document is now on its fifth edition.
  • Three other BRC Standards have since been added

  • BRC/IOP* Global Standard for Packaging & Packaging Materials – Issue 3
  • BRC Global Standard for Storage and Distribution – Issue 1
  • BRC Global Standard for Consumer Products – Issue 2
  • * Institute of Packaging

    The purpose of these four standards is to ensure that all retailer branded food items are manufactured, packaged and distributed according to a defined set of guidelines and procedures ensuring product safety and consumer confidence.

    Compliance to the Global Standard for Packaging will establish conformity with management procedures and factory standards to be used by manufacturers of packaging and packaging materials whether sourced domestically or imported directly via distributors or third party agents.

    Under EU regulation 178/2002, Food Storage and Distribution companies are now classed as Food businesses and as such have legal obligations to supply safe and legal products. The BRC standard for storage and distribution classifies such business into four distinct categories depending on the scope of the operation. Goods stored and distributed by such businesses are also subdivided into consumer products and food products.

    Regardless of which end of the food/supply chain a company operates in, due diligence is one of the most essential elements of business continuity. Achieving BRC Certification against the relevant BRC standard not only allows companies to demonstrate due diligence, it also opens business opportunities with the most powerful sector in the supply chain, the retailer. The first step to achieving certification is to learn and understand the relevant standard.

    Attendance at a BRC Global Standards training course will allow companies to benchmark their current Food Safety and Quality Management Systems against the specific requirements of the BRC standards and quantify the work required to pursue certification.

    Jul
    13
    2010
    0

    Which Quality Auditor course?

    A common question we get asked is “Should I attend the five day Quality Management Systems Auditor / Lead Auditor or the two day Internal Quality Auditor training course?”

    The answer really depends on what level of involvement the individual will have in Quality Management Systems (QMS) auditing – the two day course is for internal auditors who would normally perform internal audits of part of the QMS in addition to their normal “everyday” role. The five day course is for individuals who will have a more detailed involvement in auditing and many will have full-time roles as QMS auditors either of vendors/suppliers or third party organizations, normally auditing the entire QMS.

    The aim of the five day Quality Management Systems Auditor/Lead Auditor training course is to provide learners with the in-depth knowledge and skills required to perform external audits i.e. vendor (second party) and independent e.g., certification (third party) audits of Quality Management Systems against ISO 9001, in accordance with ISO 19011. The skills gained can also be used by internal auditors though usually these people will be from larger organizations and/or regulated industries. It is also very useful for those who themselves are audited by customers, or regulatory/certification bodies. Learners have also found it also very beneficial for those who wish to implement or manage Quality Management Systems in their own organizations to meet the requirements of ISO 9001.

    The five day course assumes the learner has a good prior knowledge of the standard, though learners can develop their understanding immediately prior to and throughout the course.

    The aim of the two day Internal Quality Auditor training course is to provide learners with a good understanding of the structure and purpose of ISO 9001 and the knowledge and skills to perform internal (first party) audits i.e., internal audits within their own organisation of their Quality Management Systems against ISO 9001, in accordance with ISO 19011. It is also useful if they are an auditee i.e., on the receiving end of internal or external audits and for learners who wish to update their organization’s approach to internal QMS auditing, making sure audits add-value and facilitate improvement.

    Learners with no prior knowledge of ISO 9001 can be accommodated on the two day course.

    On both courses, various exercises are carried out using role-plays, case studies and sample documentation. On In-House courses, the practical exercises can be carried out using the organisation’s own quality system and can be planned to finish with an internal QMS audit carried out by the learners themselves.

    Both courses are IRCA certified and delivered by TMS Consultancy, an IRCA approved Training Organisation.

    IRCA, the International Register of Certificated Auditors is the world’s original and largest international certification body for auditors of management systems. Learners on both courses are assessed against IRCA criteria. Continuous assessment is used on the two day Internal QMS Auditor course. The five day course is assessed by both continuous assessment and a written examination.

    Learners who successfully complete these training courses can go on to be registered with IRCA as auditors provided they meet IRCA’s training, education, work and audit experience requirements for the relevant auditor grade.The requirements for IRCA registration of auditors are here.

    I hope this post clarifies the differences between the two courses.

    Jul
    05
    2010
    0

    Food Allergen Alerts

    soft-shelled-egg
    Photo owned by KirkOls (cc)

    There have been seven Food Allergen incidents identified by the FSAI in the past two months. All related to undeclared allergenic content on the product label as follows:

  • One incident of undeclared soya in Yogurt Raisins and Milk Chocolate Raisins
  • One incident of undeclared milk proteins in Fruit Loaf
  • One incident of undeclared egg in Yogurt Raisins
  • Four incidents of undeclared sulphur dioxide in Sausages
  • To familiarize yourself with all Allergen legislation and to understand how to develop an Allergen Management Programme see our Food Allergen Control course brochure.

    Jun
    24
    2010
    0

    Lean Six Sigma includes more than the usual suspects!

    Lean Six Sigma has expanded its horizons to more than the usual suspects in terms of Projects. Traditionally, it was all about manufacturing and improving quality or reducing cycle times. However our Blackbelt and Greenbelt HETAC Programs have included some very unique and diverse projects in a variety of different Service and Transactional Industries. Examples include:

  • Improved Credit Card Fraud Processing by reduced input entries by 44%
  • Improved an EU Import Testing Process to meet a 23-day target
  • Green Statements – Removed the need for such a high volume of printed statements
  • Reduced number of errors relating to post being scanned to the wrong queue for distribution
  • Reduced Direct Debit Write Offs
  • PUK Code Calls – 15% reduction in customers’ calls to customer care for help
  • Standardization of Shipment Process resulting in not having to run an extra shift and resultant cost savings
  • Energy Saving Project – Reduction of carbon emissions by 23%
  • The process of screening referrals – increased management visibility and reporting of process performance resulting in less queries and non-value added investigation and tracking
  • Process Improvement is Process Improvement irrespective of the process and industry. The flexible and practical DMAIC* methodology of Lean Six Sigma has proven itself in this regard.

    In the last round of completed Lean Six Sigma projects, cost savings of €8,808,801 were achieved over seventy six projects … an average of €116k per project

    An average of €116k from projects that included more than the usual suspects!

    *(DMAIC = Define-Measure-Analyse-Improve-Control)

    May
    26
    2010
    0

    Environmental Management

    The Green Hopitality Award (GHA) is funded by the Environmental Protection Agency (EPA) under the National Waste Prevention Programme. The focus and aim of the Green Hospitality Award is to ‘green Irish hospitality’ and it is now recognised as one of the most successful programmes in Europe.

    This is a voluntary programme within the hospitality sector. Each successful member receives an award based on a set of strict criteria and can use the GHA Logo.

    Bewleys Hotel at Newlands Cross is a member of the GHA. Some of our training courses are held at this hotel.

    You are probably used to seeing the notice in hotels about towels – if you wish to reuse the towels you place them on the towel rack; if you want clean ones, you place the dirty ones on the floor. I was struck by how much more Bewleys Hotel had added to this list, the last time I stayed there.

    I took photographs of their card to show how much effort this hotel in making to green Irish Hospitality. Well done Bewleys!

    Environmental Management

    Environmental Management

    May
    17
    2010
    1

    More great NEBOSH International Certificate results

    Graduands
    Photo owned by Abulic Monkey (cc)

    The results of the March NEBOSH International Certificate exams have just been released by NEBOSH and once again we’re delighted to congratulate our students on another great set of results. The exams for this award consist of two written papers (IG1 and IG2) and one work-place assignment (IG3).

    NEBOSH exams are challlenging. The overall NEBOSH pass rates for the three exams at all centres were 58%, 58% and 89% respectively.

    The pass rates for our students were 93%, 94% and 100%, well in excess of NEBOSH averages. Well done to all students.

    If you or any of your colleagues have a NEBOSH qualification, I can definitely say you have earned it.

    We run the International Certificate course which covers International legislation but we also cover Irish legislation. Other centres run the National Certificate which is based on UK legislation. If you are considering embarking on this course, make sure you check out what legislation is covered. It is also worth enquiring about the centre’s previous results.

    Health and Safety Review by accident got the details of our course incorrect in their latest publication. The International Certificate equates to Irish National Framework of Qualifications (NFQ), Level 5.

    A NEBOSH qualification is very worthwhile for anyone considering embarking on a career in Health and Safety. We run both the NEBOSH Certificate and the Diploma courses. The next intake of people for both courses will be in September.

    Please contact akelly@sqt.ie if you require any further information.

    May
    11
    2010
    1

    The power of the simple checklist

    My son referred me to this December 2007 article by Atul Gawande, an American doctor and journalist, in the New Yorker magasine. The article is entitled, ‘The Checklist‘ with a sub heading, ‘If something so simple can transform intensive care, what else can it do?’

    This simple tool, the checklist, is introduced early on our Lean Six Sigma and Continuous Process Improvement training courses. This simple tool is no new, ground-breaking, expensive medical treatment but this article shows how powerful a tool it can be.

    Gawande’s article is well-worth reading but I have to warn you that it’s long. Here are extracts:

    A decade ago, Israeli scientists published a study in which engineers observed patient care in I.C.U.s for twenty-four-hour stretches. They found that the average patient required a hundred and seventy-eight individual actions per day, ranging from administering a drug to suctioning the lungs, and every one of them posed risks. Remarkably, the nurses and doctors were observed to make an error in just one per cent of these actions—but that still amounted to an average of two errors a day with every patient. Intensive care succeeds only when we hold the odds of doing harm low enough for the odds of doing good to prevail. This is hard.

    This is the reality of intensive care: at any point, we are as apt to harm as we are to heal. Line infections are so common that they are considered a routine complication. I.C.U.s put five million lines into patients each year, and national statistics show that, after ten days, four per cent of those lines become infected. Line infections occur in eighty thousand people a year in the United States, and are fatal between five and twenty-eight per cent of the time, depending on how sick one is at the start. Those who survive line infections spend on average a week longer in intensive care. And this is just one of many risks.

    In 2001, though, a critical-care specialist at Johns Hopkins Hospital named Peter Pronovost decided to give it
    (checklists as used in flying) a try. He didn’t attempt to make the checklist cover everything; he designed it to tackle just one problem, … line infections. On a sheet of plain paper, he plotted out the steps to take in order to avoid infections when putting a line in. Doctors are supposed to (1) wash their hands with soap, (2) clean the patient’s skin with chlorhexidine antiseptic, (3) put sterile drapes over the entire patient, (4) wear a sterile mask, hat, gown, and gloves, and (5) put a sterile dressing over the catheter site once the line is in. Check, check, check, check, check. These steps are no-brainers; they have been known and taught for years. So it seemed silly to make a checklist just for them. Still, Pronovost asked the nurses in his I.C.U. to observe the doctors for a month as they put lines into patients, and record how often they completed each step. In more than a third of patients, they skipped at least one.

    The next month, he and his team persuaded the hospital administration to authorize nurses to stop doctors if they saw them skipping a step on the checklist; nurses were also to ask them each day whether any lines ought to be removed, so as not to leave them in longer than necessary. This was revolutionary … The new rule made it clear: if doctors didn’t follow every step on the checklist, the nurses would have backup from the administration to intervene.

    Pronovost and his colleagues monitored what happened for a year afterward. The results were so dramatic that they weren’t sure whether to believe them: the ten-day line-infection rate went from eleven per cent to zero. So they followed patients for fifteen more months. Only two line infections occurred during the entire period. They calculated that, in this one hospital, the checklist had prevented forty-three infections and eight deaths, and saved two million dollars in costs.

    Pronovost recruited some more colleagues, and they made some more checklists. One aimed to insure that nurses observe patients for pain at least once every four hours and provide timely pain medication. This reduced the likelihood of a patient’s experiencing untreated pain from forty-one per cent to three per cent. They tested a checklist for patients on mechanical ventilation, making sure that, for instance, the head of each patient’s bed was propped up at least thirty degrees so that oral secretions couldn’t go into the windpipe, and antacid medication was given to prevent stomach ulcers. The proportion of patients who didn’t receive the recommended care dropped from seventy per cent to four per cent; the occurrence of pneumonias fell by a quarter; and twenty-one fewer patients died than in the previous year. The researchers found that simply having the doctors and nurses in the I.C.U. make their own checklists for what they thought should be done each day improved the consistency of care to the point that, within a few weeks, the average length of patient stay in intensive care dropped by half.

    The checklists provided two main benefits, Pronovost observed. First, they helped with memory recall, especially with mundane matters that are easily overlooked in patients undergoing more drastic events … A second effect was to make explicit the minimum, expected steps in complex processes.

    Gawande stated that Pronovost is hardly the first person in medicine to use a checklist, but that he was among the first to recognize its power to save lives and take advantage of the breadth of its possibilities.

    Gawande then described how Pronovost then took his findings on the road, showing his checklists to doctors, nurses, insurers, employers—anyone who would listen. He spoke in an average of seven cities a month while continuing to work full time in Johns Hopkins’s Hospital. But this time he found few takers.

    There were various reasons. Some physicians were offended by the suggestion that they needed checklists. Others had legitimate doubts about Pronovost’s evidence. So far, he’d shown only that checklists worked in one hospital, Johns Hopkins, where the I.C.U.s have money, plenty of staff, and Peter Pronovost walking the hallways to make sure that the checklists are being used properly. How about in the real world—where I.C.U. nurses and doctors are in short supply, pressed for time, overwhelmed with patients, and hardly receptive to the idea of filling out yet another piece of paper?

    Michigan Health and Hospital Association went ahead adopted Pronovost’s ideas in 2003. The project became known as the Keystone Initiative.

    In December, 2006, the Keystone Initiative published its findings in a landmark article in The New England Journal of Medicine. Within the first three months of the project, the infection rate in Michigan’s I.C.U.s decreased by sixty-six per cent. The typical I.C.U. … cut its quarterly infection rate to zero. Michigan’s infection rates fell so low that its average I.C.U. outperformed ninety per cent of I.C.U.s nationwide. In the Keystone Initiative’s first eighteen months, the hospitals saved an estimated hundred and seventy-five million dollars in costs and more than fifteen hundred lives. The successes have been sustained for almost four years—all because of a stupid little checklist.

    Gawande stated that Pronovost has since had requests to help Rhode Island, New Jersey, and Spain do what Michigan did.

    Gawande suggests we consider: there are hundreds, perhaps thousands, of things doctors do that are at least as dangerous and prone to human failure as putting central lines into I.C.U. patients. It’s true of cardiac care, stroke treatment, H.I.V. treatment, and surgery of all kinds. It’s also true of diagnosis, whether one is trying to identify cancer or infection or a heart attack. All have steps that are worth putting on a checklist and testing in routine care. The question—still unanswered—is whether medical culture will embrace the opportunity.

    I (Gawande) called Pronovost recently at Johns Hopkins … I asked him how much it would cost for him to do for the whole country what he did for Michigan. About two million dollars, he said, maybe three …

    This is the end of my extracts from the article. In my opinion two million, maybe three for a country the size of the USA seems like petty cash when one observes the results being achieved and in the context of the overall cost of US healthcare.

    Can you imagine if we achieved these results here in Ireland!

    I highly recommend that you read the full article, (link at top of the post).

    More here on Gawande. Gawande’s book; ‘The Checklist Manifesto: How to Get Things Right’, was released in 2009. This book reached the New York Times Hardcover nonfiction bestseller list this year.

    Any comments on use of checklists?

    May
    05
    2010
    0

    NEBOSH and Six Sigma Black Belt Courses in the Autumn

    I know we’ve only just celebrated the first of May and here I am talking about courses in the Autumn. Really I just want to get people thinking ahead for the longer courses which will commence in the Autumn. I have three courses specifically in mind and will give a little information on each:

    1 NEBOSH International General Certificate in Occupational Health and Safety

    This NEBOSH accredited course is designed for managers, supervisors and employee representatives. It focuses on international standards and management systems to provide a broad understanding of health and safety principles and practices, enabling candidates to effectively discharge workplace health and safety responsibilities.

    The course is suitable for those embarking on a career in health and safety, but also provides a valuable foundation for further professional study. According to NEBOSH this course is at Level 3 in the UK, equivalent to Level 5 on the Irish National Framework of Qualifications. (Page 2 of the following document compares qualifications in the UK and Ireland.)

    On successful completion, a Certificate holder with five years experience in a Health and Safety role may apply for Technician membership (Tech IOSH) of the Institution of Occupational Safety and Health (IOSH), the largest UK professional body in the field. The Certificate also satisfies the academic requirements for Associate membership (AIIRSM) of the International Institute of Risk and Safety Management.

    The Certificate is a 12-day taught course commencing this September, preparing candidates for exams in March 2011.

    2 NEBOSH International Diploma in Occupational Health and Safety

    The International Diploma, also accredited by NEBOSH, is designed for health and safety professionals who require a high degree of managerial and technical competence to advise on effective management of risk across the range of employment sectors. According to NEBOSH this course is Level 6 in the UK, equivalent to Level 8 on the National Framework of Qualifications.

    On successful completion, the Diploma holder may apply for Graduate membership of IOSH, (Grad IOSH). This is the first step to becoming a Chartered Member of IOSH (CMIOSH). This qualification is also accepted by the International Institute of Risk and Safety Management as meeting the academic requirements for full membership (MIIRSM).

    The International Diploma is a blended learning course with 14 workshop days commencing this October, preparing candidates for examinations in January 2011 and July 2011.

    3 Six Sigma Black Belt, HETAC accredited

    Six Sigma is a comprehensive and highly effective strategy for achieving and sustaining business success. Six Sigma delivers bottom line savings, project by project, in an organised, proactive and highly transparent manner. Six Sigma is driven by a close understanding of customer needs, disciplined use of knowledge, facts and statistical analysis and diligent attention to a methodology to improve or reinvent business processes.

    Our Black Belt 20 day programme consists of 4 days training per month, over 5 months. The unique feature of this Black Belt programme is that HETAC certification is only achieved on completion of a major project, documenting application of the learning tools and evidence of the savings generated. Typical Black Belt projects are yielding savings of €250,000 per project. The course is at Level 8 on the National Framework of Qualifications.

    Our autumn Black Belt course is commencing in October. Training will finish in March 2011 with project completion due within 12 months.

    We will have a wide range of shorter courses on offer over the coming months. Since these three courses are longer and thus the decision is bigger in terms of time/cost, I thought it was worthwhile to write separately about them. The three titles above are links to the relevant web page giving more detail on each course.

    Please contact me, lcollison@sqt.ie if you have any queries.

    Apr
    26
    2010
    0

    Recent Six Sigma Projects save almost €9 million

    Congratulations to all recent recipients of HETAC awards for their Six Sigma training. Last month ninety people received awards over the four HETAC accredited Six Sigma courses.

    Seven people completed Black Belt training. Their projects realised cost savings of on average €300,576 per project.

    Four people completed Back Belt, Service and Transaction projects. Their projects averaged €71,968 savings.

    Sixty Five people completed Green Belt, HETAC level 7 projects. The average cost saving was €98,722 per project.

    Fourteen people completed the Green Belt HETAC level 6 course, which involves a case study rather than completing a project.

    In all cost savings of a total of €8,808,801 were achieved over seventy six projects.

    There are many other Six Sigma projects underway. People are working hard completing these and achieving more very tangible cost savings for their companies. These savings are critical for the survival of many companies in the economic realities of 2010 Ireland.

    Without doubt, Six Sigma methodology is now proving to be a very important tool.

    Apr
    19
    2010
    0

    NEBOSH Diploma exam results

    Congratulations to all on the excellent results in the January exams for the NEBOSH International Diploma in Occupational Health & Safety.

    This is a supported distance learning course. Generally two courses commence each year in September and January. Each student takes three examinations, (Units A, B and C), and then completes an assignment (Unit D). Exams are held twice per year (January and July), at centres throughout the world. Successful completion of all four Units leads to being awarded a NEBOSH Diploma. The award is at Level 8 on the National Framework of Qualifications.

    The NEBOSH Diploma exams are challenging exams. The overall NEBOSH pass rates for January for all exam centres were as follows:
    Unit A 39%
    Unit B 51%
    Unit C 45%

    I’m delighted that the pass rates for SQT candidates for each Unit exceeded the NEBOSH average:
    Unit A 53%
    Unit B 71%
    Unit C 54%

    In fact, the latest cohort of students who commenced in September 2009 and sat the Unit A exam in January, achieved an overall pass rate of 64%. When one compares this to the NEBOSH average pass rate of 39%, one sees what a good result they achieved.

    Well done to everyone, all the hard work paid off. Well done also to the tutor for this course, Finbarr Stapleton.

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