Don’t Ignore the Human Factor When Becoming More Automated

by | Dec 22, 2015 | Ice Cream Consulting

Excellent article in the September issue of Dairy Foods written by Allen Sayler starting off by stating, “Production personnel’s hands-on knowledge of how equipment works contributes to food safety.” The message balance technology with people, one does not supersede the other. Staff training is still the most important factor in keeping a clean, safe manufacturing facility and should not be looked at as an area to cut costs.

Just because you add automated equipment, at the end of the shift, equipment still needs to be broken down and cleaned. While in operation, setting needs to be monitored, sensors need to be calibrated, valves need to cleaned by hand and compromised problem areas of the line need to be immediately corrected. When we read about people getting sick or dying from food poisoning, automation and equipment is not the initial culprit, it’s people.

I’m not suggesting that personnel are deliberately turning their back on proper procedure and protocol, but rather they are not being properly trained on a regular and consistent basis. Just because a linesmen is proficient in their job and doing it well for many years, does not suggest they do not require a refresher training sessions. That is the ten dollar issue on a multi-million dollar production line.

State of the art automation are great useful tools to help mitigate a potential problem area, but not a stop gap. When companies invest in automation, they are quick to justify the expense by concluding labor cost can be reduced. Automation is designed to weak area in the line, maintain product consistency, speed up production and the overall cost of an item.

However, it will not correct contaminated water dripping from a ceiling vent into an open cup, monitor cross contamination or detect when a dirty rag used around a floor drain next used on a product valve or production line surface area.  

Contact Darryl, he can help update your manufacturing facility, recommend equipment and train your staff in Good Manufacturing Practices.

Darryl David
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