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Employee compliance suggestions for quality, security and safety

  • 1.  Employee compliance suggestions for quality, security and safety

    Posted 09-22-2023 12:59

    I know that this is the technical forum but I am having a hard time finding worthwhile suggestions from production level managers on how to help production employees pay attention to detail in their daily work.  I have created in-depth SOP's with associated checklists based on each SOP, re-written the employee handbook, and scolded (firm but fair obviously)  my production staff.  We are struggling to find ways to make sure that the little things aren't forgotten while still not feeling micromanaged or a lack of independence.  We are small so production staff wear many hats throughout the week.  Any suggestions that have worked for you all would be wonderful.  Also sorry for hi-jacking a tech forum.



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    Landon Swanson
    Head Brewer
    Pueblo Vida Brewing
    Tucson AZ
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  • 2.  RE: Employee compliance suggestions for quality, security and safety

    Posted 09-25-2023 13:21

    What details exactly? Can you demonstrate with data or some solid logical argument that the details in question are important? I've found that there is often more than one perfectly acceptable way to do something. I've had arguments about small details and came to realize that it's not worth it most of the time. Obviously there are many things that are super important and just can't be neglected. If the detail involves important sanitation procedures or CO2 purging for example then compliance is pretty essential. Other times there can be a variety of equally acceptable variations. So I guess what I'm saying is that first you should consider whether you're maybe just being stubborn about some minor thing. Assuming you're not, my advice would be to show the workers some type of valid information to prove why the details are important. No one likes 'do it this because I say so' as a reason. Have discussions about the SOPs with the staff and make adjustments if necessary. I think people will have better attention to detail if they 1. have input on the process itself and 2. trust that what they are doing is the best practice with a data driven and logical defense. 



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    Bill Hyland
    Head Brewer
    Bozeman Brewing Co.
    Bozeman, MT
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  • 3.  RE: Employee compliance suggestions for quality, security and safety

    Posted 09-25-2023 14:03

    Landon,

    Without giving specific recommendations to you for your particular situation, which is unique to you, your company, your processes, and your expected performance from your employees, I will say that finding the "right" and "qualified" people to put into specific areas in a small craft brewery can be daunting. In my 28 years in the industry, I have come across several situations in which doing that specifically was quite hard. We (craft brewers) as a whole tend to promote individuals, and/or delegate certain new responsibilities to those who have been with the company longer, or are higher up on the ladder, without ever really looking at the facts as to whether or not that is the "right" person for the job. I have found that no matter how long someone has been in the business, or how great and reliable of an employee that person is, there are unique differences in all employees to how well they pay attention to what you call the "little things". It is the difference between someone's ability to observe, process, and execute the necessary tasks for each specific role. Some people have a better ability to do those things than others. Just because someone is phenomenal in the brewhouse with following recipes, SOP's, and so forth, doesn't necessarily mean they will be great at watching a can filler from de-pall to end of line, and keeping their eyes and ears open from one end to the other. In the world of smaller craft breweries, we are very reliant on our employee's ability to multitask and perform a multitude of different duties across the production, cellaring, and packaging platforms. Some people just have that ability naturally. Other people will be able to pick those things up with training and repeatability, but others will just never quite be that person you really need in that role. This sounds to me like you are maybe in that scenario with someone who is a fine employee, but just can't quite take it to the next level of responsibility and shine in multiple roles. 

    This is always a tough decision to make, but I can tell you that the people who can do all those things you need are out there, and unfortunately if we don't put the right people in the right places, the company you represent will suffer, by allowing the wrong people to stay in the wrong roles amongst production and packaging staff. When our bosses/ownership wants us to be as efficient and productive as possible, sometimes we need to make that hard decision to let someone go to bring in someone more suited for all the tasks required of them, not just most of the tasks. Again, this is a very hard decision to make, but business is business, and usually the person who is great at one thing but not at another will actually find more happiness elsewhere when they are utilized for their strengths instead of putting them into roles, they will never quite fit into.

    (As a side note, I have been in the industry for more than 28 years and have been the hiring manager at several different breweries for more than 1/2 of that time. I have found myself in the same position as you on several occasions and have also had to make the hard decision to let several people go for very similar reasons throughout my career. It is never fun, but if you don't or can't do that, then you may also not be living up to your expectations by ownership.)

    Again, your role and your business are unique, and I don't want to assume that my perspective on your problem is accurate, but hopefully it is at least somewhat helpful, and you can use the information for your own purposes.



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    Brett Kintzer
    Brewmaster
    Swashbuckler Brewing Co.
    Reinholds PA
    (484) 755-0265
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  • 4.  RE: Employee compliance suggestions for quality, security and safety

    Posted 09-25-2023 15:50
    Hi Landon,

    The Brewers Association (BA) has some really good info on preventing workplace violence that can be seen here: https://www.brewersassociation.org/educational-publications/working-in-the-age-of-rage/

    Hope this helps!

    Dana

    --

    Dana Johnson (He/Him)

    Technical Director, Craft Brewing

    Diversey – A Solenis Company

    9152 Yosemite St.

    Henderson, CO 80640

    Office: 800.233.1000, Cell: 303.518.2857

    dana.johnson@diversey.com

    LinkedIn | diversey.com

    Diversey is now part of Solenis – Find out more

    Solenis is a 2023 US Best Managed Company.


    Disclaimer: This email contains information which may be privileged, confidential, proprietary, trade secret and/or otherwise legally protected. If you are not the intended recipient, please do not distribute this email. Instead, please delete this email from your system, and notify us that you received it in error. No waiver of any applicable privileges or legal protections is intended, nothing herein shall constitute such a waiver, and all rights are reserved.






  • 5.  RE: Employee compliance suggestions for quality, security and safety

    Posted 09-25-2023 15:51
    Hi Landon,

    I attached the wrong link.  Here is the one I meant to send you:


    Dana

    --

    Dana Johnson (He/Him)

    Technical Director, Craft Brewing

    Diversey – A Solenis Company

    9152 Yosemite St.

    Henderson, CO 80640

    Office: 800.233.1000, Cell: 303.518.2857

    dana.johnson@diversey.com

    LinkedIn | diversey.com

    Diversey is now part of Solenis – Find out more

    Solenis is a 2023 US Best Managed Company.


    Disclaimer: This email contains information which may be privileged, confidential, proprietary, trade secret and/or otherwise legally protected. If you are not the intended recipient, please do not distribute this email. Instead, please delete this email from your system, and notify us that you received it in error. No waiver of any applicable privileges or legal protections is intended, nothing herein shall constitute such a waiver, and all rights are reserved.






  • 6.  RE: Employee compliance suggestions for quality, security and safety

    Posted 09-26-2023 11:52

    Hi Landon,

    You're essentially trying to change the company culture, which is difficult but not impossible to do. You've done the first step, which is to ensure all written materials are up to date and available. The next step is to get buy-in from the production managers, who are the ones who need to be enforcing protocol on the floor. I would encourage them to utilize those checklists in this way: at end of day, production operators cannot leave until the production manager has signed off on the closing checklist. The production manager must go through and make sure everything has been performed correctly. Only then is the operator excused to clock out. You can do something similar for cleaning prior to a production run. Lastly, you can provide trainings to your production staff and empower them to be champions of quality and safety in the brewery.

    I found this book to be very helpful: Quality Management by Mary Pellettieri . Good luck to you!



    ------------------------------
    Michaela Kazek
    Quality Manager
    Ballast Point // Kings & Convicts Brewery
    San Diego, CA
    ------------------------------



  • 7.  RE: Employee compliance suggestions for quality, security and safety

    Posted 09-26-2023 12:45

    Further Michaela's post, I'd like to point out that the book Quality Management by Mary Pellettieri is available in the MBAA bookstore on this website, and MBAA members save 10%.  



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    Lars Larson
    Master Brewer
    Trumer Brewery
    Berkeley CA
    (510) 526-1160
    ------------------------------



  • 8.  RE: Employee compliance suggestions for quality, security and safety

    Posted 09-29-2023 14:36

    Hi Landon,

    Based on your company's website, you are quite small so it is especially acute. I work in production staff of three so we wear a lot of hats and all have multiple responsibilities during the day. I feel your challenge. Especially as we have multiple types of brites and CCVs and each are slightly different in terms of procedures for CIP/Transfers/Yeast Cropping/ETC. Our approach is to ask questions on status and follow up on important actions. It is how I was trained and our Head Brewer does this too. The key is that we have a very positive work environment and understand that mistakes happen. If they do, we work to correct and plan for not messing up in the future. With this solutions oriented approach, we can admit errors and not have surprises of things done improperly.

    As others have said, reinforcing the reasons for why we do things a certain way seems to get buy in. 

    I've been thinking about checklists for tasks that are quick and easy to read. No one wants to have to read a full detailed SOP every time for doing daily tasks but having a checklist gives guidance to help things not get forgotten. 



    ------------------------------
    Bryan Doran
    Brewer
    Cambridge Brewing Co
    Cambridge MA
    ------------------------------



  • 9.  RE: Employee compliance suggestions for quality, security and safety

    Posted 10-02-2023 14:36

    Hi Landon,

    Safety through written procedures is important, but most practical brewers will agree that SOPs are not  frequently referenced after the first few reads. Being safe requires diligence.  Check out this link for some ideas on how to make Toolbox Talks a normal part of your team's daily routine.

    Cheers,

    Ashton



    ------------------------------
    Ashton Lewis
    Manager of Training and Technical Support
    BSG Craftbrewing
    MBAA District Great Plains, Technical Chair
    Springfield, Missouri
    (417) 830-2337
    ------------------------------



  • 10.  RE: Employee compliance suggestions for quality, security and safety

    Posted 10-03-2023 16:21

    To add to Ashton's post, the MBAA Safety Committee continually generates great content in monthly Toolbox Talks specific to our industry. Here's a link the archive: https://www.mbaa.com/brewresources/brewsafety/Pages/toolboxtalks.aspx. This makes it really easy to feed your team monthly content to discuss! 



    ------------------------------
    Marcus Powers
    Co-Founder | CEO
    Zipline Brewing Co.
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  • 11.  RE: Employee compliance suggestions for quality, security and safety

    Posted 10-04-2023 00:06

    Marcus and I are both officers in District Great Plains and I owe the MBAA a little explanation about my previous post!  I suggested Tool Box Talks and provided an external reference without acknowledging the MBAA's archive about this useful tool.

    Marcus, thank you for pointing out what I did not.  My intent of providing an external link was to give props to what the MBAA has, but I forgot to close the loop!

    I think I owe someone a beer and will be happy to pay up at the Bierstube in Seattle :-).

    Cheers, Ashton



    ------------------------------
    Ashton Lewis
    Manager of Training and Technical Support
    BSG Craftbrewing
    MBAA District Great Plains, Technical Chair
    Springfield, Missouri
    (417) 830-2337
    ------------------------------



  • 12.  RE: Employee compliance suggestions for quality, security and safety

    Posted 10-03-2023 21:03
    I agree with Landon , One thing we did try to do was have department heads present SOPs to other departments and have discussions, along with discussions we would always look at adapting and changing SOPs to be safer and easier to understand . Easier Procedures are more likely to be followed .


     

    Thanks '
    W Scott Pyatt
     






  • 13.  RE: Employee compliance suggestions for quality, security and safety
    Best Answer

    Posted 10-01-2023 18:43

    You have received some really great responses here, consider which to use and how.

    Because of my experience as a worker before becoming a certified safety professional, I'll give you a different perspective.

    First, why is most important as was mentioned. Whether in manufacturing or construction, that has been my most important focus during training. Why applies to process quality and safety, and security. Sometimes you will find that why is the same for all three, sometimes it won't apply to more than one. Find the correct message and don't change it unless the procedural reason for why changes. Feed the inquisitive mind.

    To build on this, the best employee you will have is always asking why. Those who actively seek to learn will make your brewery better. I have been working across many industries and job categories for more than 40 years, and my best days are when I am asking those around me why.  My worst are when I don't ask. Because learning always leads to improvements, and sometimes it will just be something subtle which is the improvement. 

    Including the workers in the creation of the procedures is crucial. Yes it helps them to buy in. But I think the most important thing I learned was that having a discussion about each step in the process helps you know that the step is correct, but it also helps the workers understand it is correct as well. And if you are both wrong then the correction will be accepted as important. 

    Next are the aspects of how the brain works. Is the person purposely shortcutting to save time or energy, or simply for laziness? That is a specific kind of problem.

    Or are these unforced errors? Studies are finding all manner of reasons why things go wrong. An example my boss keeps quoting that a manufacturing process study found that an error occurs about every 1000 times it was performed. This was a day in day out repetitive process which should have achieved zero errors, and this was the best result they found while studying manufacturing processes. As you move to task which are less frequent the frequency of error quickly went to performing and having single digit repeats of the task before an error. For one off tasks the chance for an error was determined to be 1 in 3 or 4. This is typical in construction because a lot of the work is flexible to the location. Ever go to a countertop or cabinet installer to look at their inventory and notice the back area where they have the precut or custom products which didn't fit during the attempted installation? If those professionals can have problems, so can a professional brewery employee. Which is where your checklists come in. Whether they are to account for each of your ingredients going into the batch or a lock out tag out procedure to make sure the worker is protected. This sounds so silly to even mention; I had a checklist for my brew day. When I achieved boil I wrote the time on my recipe sheet. Then I added the time that each addition would happen and knock out had to start and cooling had to be achieved. If I missed the times I would note the error so I could evaluate the change that my error caused. Evaluating quality vs. performance. The good employee doesn't argue about this, they embrace it because they are seeking to achieve their best. Continuous improvement; if someone isn't aiming to improve they may not be a good fit for the task they have assigned to be perfect at.

    NFPA 70E electrical safety has Annex Q in which the worker is to evaluate their fitness to work. The annex walks through things which can lead to errors; it is focused toward safe performance of electrical work, but I have applied it to all sorts of tasks with a lot of success. People don't want to say that something is wrong and will keep them from performing their best, but if we talk about it then adjustments can be made to eliminate errors.

    I can point you to some great articles for more details about performance if you like. Smart safety professionals have been addressing the theory that how our brains work has a direct impact of our quality of work. Ask anytime.

    I hope this helped,

    Tony McCrimmon



    ------------------------------
    Russell McCrimmon
    Safety Consultant
    Brewery Safety Consulting
    Aurora CO
    (303) 680-8395
    ------------------------------