Sheldon's — Induction Answers (Trainer Copy)

1. Whose responsibility is it to ensure you and others are safe within the workplace?

Everyone's. Health and safety is the responsibility of every member of staff — you must look after yourself and the people working around you.

2. Why should you report all accidents to your manager?

So the accident is recorded and investigated, the hazard can be removed, and the same accident does not happen to someone else.

3. How can you prevent slips, trips and falls?

Good housekeeping, clearing boxes and clutter from walkways, cleaning or reporting spills straight away, using safety signs, wearing safety shoes, reporting poor lighting and damaged floors, and following the procedures you have been trained in.

4. Why should you avoid messing around?

Horseplay and pranks cause accidents. In a bakery with moving racks, hot surfaces and machinery, messing around can seriously injure you or someone else.

5. What should you do if you find a spillage and you are busy?

Either clean it up or report it immediately — never walk past it and leave it for someone to slip on.

6. Name two things that make a floor unsafe to walk on.

Any two of: it is wet or slippery, it is uneven or damaged, there are obstructions or boxes on it, or there is not enough lighting to see it.

1. What could you use to help you lift items?

A mechanical aid or a trolley — or another person. Ask your supervisor if you are unsure what is available.

2. Why is it important to use the correct lifting technique?

To prevent injury to yourself. Poor technique causes back injuries, hernias, strains and fractures — many of them permanent.

3. How should you move a load that is big and heavy?

Do not attempt it alone. Push or pull it if you can, use a trolley or mechanical aid, or get help. Never carry something that blocks your vision.

4. What injuries could you cause by not using the correct lifting technique?

Back injuries, hernias from straining, strains to muscles and joints, wounds from sharp or rough items, and fractures from dropped loads.

5. What four things do you consider when assessing a lift?

The task, the load, the environment, and the capability of the individual doing the lifting.

6. Should you twist your body while carrying a load?

No. Pivot with your feet instead of twisting your back, and keep the load close to the centre of your body.

1. When must ear defenders be fitted?

Before you enter the bakery — not once you are already inside the noisy area.

2. How many times can a pair of earplugs be used?

Once. They are single use items and must be disposed of safely at the end of your shift.

3. Can you cut the cord off, or alter the earplugs to make them more comfortable?

No. Do not modify ear defenders in any way and do not remove the cord that attaches the earplugs together.

4. Why do you pull the outer ear out and up before inserting an earplug?

So the earplug can go around the bend in the ear canal and sit deep enough to protect your hearing.

5. Why are ear defenders provided at all?

Because the noise levels in those areas meet or exceed the lower limit for noise, and repeated exposure damages hearing permanently.

1. What is a pest?

A creature that is harmful to humans or farm animals, or one that interferes with our home or work activities.

2. Why does a pest problem matter so much in a bakery?

Pests spread germs, spoil food with droppings, make the place a bad place to work, ruin the company's reputation and can get the business closed down.

3. Name three things you can personally do to keep pests out.

Keep doors and windows closed, keep your work area clean and tidy, report signs of pests quickly, and tell your work mates about bad conditions.

4. What is the most common way of knowing you have a cockroach problem?

Seeing them moving around — usually at night. Dead cockroaches are also a good sign that they are living on the premises.

5. How small a gap can a rat fit through?

15mm. Mice need even less, so gaps and open doors must not be ignored.

6. You spot bird droppings in the warehouse. What do you do?

Tell your line leader quickly, so the birds can be removed safely and the area cleaned before anything is contaminated.

7. Whose responsibility is pest control?

Everyone's.

1. Where must high visibility clothing be worn?

In any outdoor area, except the Bakery 1 and Bakery 2 car parks, the smoking areas and defined walkways.

2. Is it acceptable to wear your hi-vis unfastened or over one shoulder?

No. It must be worn correctly and fully fastened to the front.

3. You need to cross the yard quickly and your vest is inside. What do you do?

Go and get it. You must not enter those areas without high visibility clothing, no matter how short the trip is.

4. Why does the company insist on hi-vis outdoors?

So drivers of vehicles and forklift trucks operating in the external areas can see you.

1. You drop a glass jar on the line. What is the very first thing you do?

Inform the manager immediately. Production is stopped straight away.

2. How big an area is sealed off after a breakage?

10 metres (30 feet) in every direction from the incident, using the hazard tape from the glass breakage kit.

3. Where does contaminated food waste go?

Bagged, labelled as waste and put in the General Waste container — never the Food Waste Compactor.

4. Does this procedure apply if you break your glasses?

Yes. Lost or broken personal spectacles and contact lenses in the manufacturing areas are covered by the same procedure.

5. Can you leave the area to fetch something while it is sealed off?

Not with any food materials or equipment, and not before checking your clothing and footwear for contamination. Nothing leaves without the manager's permission.

6. What happens to the broken glass once it is swept up?

It is bagged, labelled as Glass/Plastic, dated and given to the Technical Manager, and a sample is retained with the incident report.

1. What is an allergen?

Something that can cause an allergic reaction in someone sensitive to it — anything from a rash to anaphylactic shock.

2. How many major allergens are there, and how many do we use on site?

There are 14 major allergens. We have five on site: sesame seeds, lactose (cheese), egg, gluten and soya — plus sulphites below 10ppm, which are not treated as an allergen.

3. Which is the most dangerous allergen we have on site?

Sesame seeds, used on top of burger buns.

4. What colour is all allergen equipment and clothing?

Red — aprons, overshoes, containers, scoops, brushes, utensils, waste bins and the lined floor areas.

5. What is a label declaration, and which allergens does it control?

A statement on the packaging telling customers what allergens are in the product. It controls gluten and soya, which are in every product. It is NOT enough for sesame or milk.

6. Can cheese topped and sesame topped products be made at the same time in the Allergen Room?

No. Under no circumstances. They must always be produced at separate times.

7. Which line are allergen products wrapped on?

Line 1, the allergen line, with a full clean down after each allergen product.

8. Dough has been in the topping room. Can it be reworked?

Never. It goes in the waste bin and to the compactor at the end of the day's production run.

9. You spill sesame seeds on the floor. What do you do?

Clean it immediately using the red allergen cleaning equipment, report it to a supervisor or manager, and record it on a Non-Conformance Form.

10. What gap is needed between allergen and non-allergen products in a continuous oven?

A 4-pan gap — also between two different allergen products.

1. How many racks may you normally move at once?

One — whether it is full or empty.

2. What is the only exception to that rule?

Up to 4 EMPTY racks between the ovens in Bakery 2, inside the lined area only.

3. Can you push 4 racks if they have trays in them?

Never. The exception applies to empty racks with no trays.

4. What does “free-wheeling” mean and why is it banned?

Pushing a rack and letting go so it rolls on its own. A loaded rack is heavy and cannot be stopped — it will injure whoever is in its path.

5. Before pushing racks between the ovens, what must you check?

That no one is in the area, and that you are holding the first rack with two hands. Then walk at a steady pace.

1. Which goes on first — your hairnet or your food safe jacket?

The hairnet, always. And you must not take the hairnet off while you are still wearing the jacket.

2. Where do your outdoor shoes go?

Inside your locker. Never underneath the lockers.

3. Can you keep a sandwich and a bottle of pop in your locker?

No. No food or drink may be stored in lockers, and none may be consumed in the changing rooms.

4. Why is glass banned from lockers?

Glass in a food factory is a serious contamination risk — a breakage triggers the whole glass breakage procedure.

5. Can outdoor coats hang next to food safe jackets?

No. Outdoor clothing and food safe clothing must never be mixed on the hangers — they are clearly labelled.

6. Will anyone check?

Yes. The company conducts random locker audits at regular intervals.

1. How long should you scrub your hands for?

At least 20 seconds.

2. Hot, warm or cold water?

Hot or warm — never cold.

3. Which two places do people most often miss?

Between the fingers, and the fingernails.

4. What comes after rinsing?

Sanitise, then dry with a paper towel or air dryer and put the towel in the bins provided.

5. Name three times you must wash your hands during a shift.

Before starting work and entering production, after using the toilet, after breaks, after handling waste or cleaning, and after leaving an allergen area.

1. What is the correct order for putting on your work wear?

Hair net (and snood if you have a beard or moustache), trousers, safety shoes, sanitise hands, then food safe coat.

2. Why does the hair net go on first?

So no hair falls onto your food safe coat once it is on — that is why you also must not remove the hair net while wearing the coat.

3. When do you sanitise your hands in the sequence?

After your safety shoes, immediately before putting on your food safe coat.

4. You have a beard. What extra item do you need?

A snood.

1. A guard is missing from a machine. Can you use it?

No. Never work on a machine where a guard is missing — report it.

2. Can you clean a machine while it is running?

No. Nothing is cleaned unless it is isolated.

3. Where are the emergency stop buttons in your work area, and what do they do?

Trainee should be able to point them out and explain that they stop the machine or line immediately.

4. Can you drive a forklift truck if you are confident you know how?

No. Never drive an FLT without a licence.

5. Can you bring your own tools in from home?

No. Tools and equipment must never be brought in from home.

6. What must you do with a damaged tray or rack?

Do not use it. Inspect trays and racks before use and put damaged ones in the place set aside for repair.

7. Where are the fire escapes and who are the first aiders?

Trainee should be able to name the fire escapes for their area and identify the site first aiders.

8. Can you carry a knife in your pocket?

Never carry a knife or any other sharp object on your person.