What to you do when there are repetitive holds due to human error?
I am noticing repetitive holds in the facility due to human error despite of training and retraining (such as missed following SOPs, ignorance, lack of eye and mind at work etc.) at different product lines. How would you mitigate these issues. I am thinking more into psychological way like human nature and behavior, sense and urgency to respond to tasks. It is also related to food safety culture.
Any idea to deal with?
Thank you!
Is it the same operator(s) making these mistakes consistently? At a certain point if retraining isn't working and they're still negligent, you may need to start thinking about transferring or even terminating the employee.
If the issue is widespread, perhaps your training program is to blame! You may also need to think about how comfortable your staff is during the day. Are enough breaks given? Is the work area tolerable (good temperature, ability to sit or cushioned mats to stand on)? People loose concentration if they are uncomfortable. Really, the list is endless for reasons why staff may be neglecting their responsibilities. It can be hard to diagnose unless you're there seeing the place in action.
Have you ever tried talking with the staff to get a feel for their attitudes or perception of the work place?
Its two things 1) Trainings are not effectively done; Or 2) The employees have a negative attitude to the work or the working environment. if its 2 then consider disciplinary action (this process would uncover the root cause) or replacing the workers.
Regards
I think this point more related to the root cause analysis you do, do you follow a specific tool to solve your problems?
When you get the most realistic reasons and start adding actions try to involve your workers to share their thoughts how to solve these issues, when you get ideas, filter them, set rules and add your own punishment and rewards based on this.
I am noticing repetitive holds in the facility due to human error
Translation: systematic error.
There should be a company-wide solution for the problem.
To add to previous posts, are you communicating these holds effectively so that all relevant people in the department are aware of repeated problems with their production?
I would be attending their team meetings, posting on notice boards and talking to individuals and their supervisors. If things don't progress then use the disciplinary process.
Kind regards,
Tony
... How would you mitigate these issues. I am thinking more into psychological way like human nature and behavior, sense and urgency to respond to tasks. It is also related to food safety culture.
Any idea to deal with?
Thank you!
Are you implying with the bold part ^ that you believe people are deliberately ignoring their duty because they don't take food safety seriously?
I suggest you take a good look at the work environment, as Brothbro mentioned. If the problem is consistently happening with the same persons or in the same area, perhaps you should spend some time in that area and see for yourself if there are other factors involved. For instance, if you require tasks to be accomplished during a specific timeframe, does the employee reasonably have enough time available to perform all tasks within that timeframe or is their workload too much? Is the area too hot or too cold, making the employee uncomfortable and less likely to pay proper attention? Finally, is this person really suited for that position or level of responsibility?
Is this repetitious work done over and over day to day? Or is this new task all the time and employees having to wear more than one hat? I found that using our write ups help before termination. Verbal, Written, Action Plan, One day without pay, Termination. It's becoming harder and harder to find workers that are competent to do the job. Maybe find out their learning styles. Some I have to read the test to, some I have to show them a video, some I have to come up with some scenarios where something went way wrong because the person did not follow a step in the SOP. A lot of staff have an SOP to go by, but most employees learn hands on. We find that we have to train on the paper work, then hands on, then follow up with the SOP again so it clicks. To enhance your food safety culture you could try some surveys. Find out things from your employees in a drop box. Sometimes anonymously, sometimes not. Depending on the survey and the expected results. Get a list of food safety and quality issues you are having day to day and present them to your employees and get their feedback. Sometimes I find I have to buy something small to make their job doable. Do they need stress mats, do they need extra breaks, if you can find away to enhance the culture this will help tremendously.