Sheldon's — New Starter Induction Pack

Slips, trips and falls are a major category of accidents within the workplace and result in a significant number of injuries. Most of these accidents occur by:

• Obstructions on the floor
• Wet, slippery or uneven floors and pathways
• Lack of signs
• Inadequate lighting
• Misuse of equipment
• Poor and inadequate footwear

The most effective method of prevention is to eliminate the hazard — keep your work area clean and tidy, with equipment in its correct place and away from walkways.

Practical steps to prevent accidents

Workplace behaviour

Behaviour in the workplace can contribute to slips, trips and falls. It is your responsibility to:

• Avoid messing around or playing pranks
• Not use tools or equipment unless you have been trained
• Never run in the workplace — always be aware of your environment and surroundings
• Always use handrails to help you maintain your balance when using stairs
• Never take shortcuts over or under equipment

Almost a quarter of all accidents reported to the authorities each year are associated with manual handling. Virtually all workplaces have staff involved in moving and lifting as part of their routine work.

Manual handling injuries are often the result of poor lifting techniques. The most common injuries are to the back, but there are others:

• Hernias — injury in the abdomen caused by straining
• Wounds — cuts, scratches or bruises from handling sharp or rough items
• Fractures — broken bones caused by dropping heavy items
• Strains — muscles and joints injured by being overworked

Assessing the task

The company has carried out health and safety assessments and, where possible, installed machinery to remove the risk. Some tasks still require manual handling, so you must assess the task and use the correct lifting technique.

Whenever you need to lift or carry something, consider:

• The task to be carried out — what is the job?
• The load to be moved — how big is the object? How heavy is it?
• The environment — what is the flooring like?
• The capability of the individual — how strong is the person?

Correct lifting technique

• KEEP THE LOAD CLOSE — keep your arms tucked in
• DO NOT TWIST YOUR BODY — avoid stooping, bending or leaning back. Pivot rather than twist
• DO NOT BLOCK YOUR VISION — avoid carrying large objects that restrict your line of sight
• PUSH OR PULL IF YOU CAN — if you can push or pull the item rather than lift it, you should
• LIFT WITH YOUR LEGS — keep a good stance, good balance and stay steady on your feet

Steps to remember

The lift, step by step

• STAND as close to the load as possible. Spread your feet to create a stable base
• BEND your knees and keep your back in a natural line — don't bend the knees fully
• GRASP the load firmly
• RAISE your head as you start to lift
• LIFT the load, using your leverage, momentum, balance and timing for a smooth action. Move your feet
• HOLD the load close to the centre of your body

ALWAYS make sure you have enough space to work in.

Ear defenders are provided to all staff working in areas where the noise levels meet or exceed the lower limit for noise.

• Ear defenders are single use items
• They must be fitted to your ears before entering the bakery
• Dispose of the packaging once opened
• Dispose of the ear defenders safely at the end of your shift
• Do not modify the ear defenders in any way
• Do not remove the cord that attaches the earplugs together

How to properly insert earplugs

As a food factory it is very important that we work in hygienic and pest free conditions. If you see signs of pests in or around the factory, tell your team leader or manager quickly.

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

Why is pest control so important? Pests in food premises spread germs, spoil food with droppings, make the place a bad place to work and ruin the company reputation. They can even get the business closed down.

Insects

Birds and rodents

PEST CONTROL IS EVERYONE'S RESPONSIBILITY. If you suspect an infestation, our pest contractor must be called in to control and eradicate it and prevent contamination to food.

High visibility coats and vests must be worn in any outdoor area, with the exception of:

• Bakery 1 car park
• Bakery 2 car park
• Smoking areas
• Any defined walkway

You must not enter any other areas if you are not wearing high visibility clothing. Coats and vests must be worn correctly and fully fastened to the front.

A glass or hard plastics breakage is a serious incident. If a breakage occurs, all reasonable steps must be taken to isolate and remove possibly contaminated goods and to investigate the reason for the breakage.

This also applies if a staff member or visitor to the manufacturing areas loses or breaks personal spectacles and/or contact lenses.

Manager's actions

• STOP PRODUCTION IMMEDIATELY
• Ask all staff in the area to examine their clothing and footwear before leaving, and clean off any contamination inside the area
• Get the glass breakage kit, put on the disposable clothing and overshoes, and seal off 10 metres in every direction with hazard tape
• No food materials or equipment leave the area without the manager's permission
• Examine the area thoroughly and sweep up the broken glass or plastic with the kit's dustpan and brush. Bag it, label it Glass/Plastic, date it and give it to the Technical Manager
• Bag all suspect contaminated food as waste and dispose of it in the General Waste container — not the Food Waste Compactor
• Thoroughly clean all suspect contaminated equipment before re-use, and complete any repair work. If in doubt, do not start production
• Remove the disposable clothing slowly inside the sealed area, bag it with the used kit and take it to the General Waste container
• Thoroughly clean the floor and recheck for contaminants
• Complete the Manager's Serious Incident Report
• Retain a sample of the glass/plastic with the report and pass it to the Technical Manager
• Replace the used kit — obtain a new one from Technical

The glass breakage kit

Out of hours, leave the kit, report and sample in the Technical Office — it will be replaced the next day.

The control of allergens is a very important process with many rules. As a company we take allergen control very seriously and expect all our employees to be equally diligent.

An allergen is something that can cause an allergic reaction in someone who is sensitive to it. The reaction can be anything from a rash to anaphylactic shock.

The allergens we use on site

SOME ALLERGENS ARE MORE DANGEROUS THAN OTHERS, AND SOME CAN CAUSE DEATH TO THOSE WHO ARE SENSITIVE. THAT IS WHY WE HAVE RULES WE MUST FOLLOW.

• Sesame seeds — only used on top of burger buns. The most dangerous allergen we have on site
• Lactose — found in the milk in the cheese we use
• Sulphites — present in fruit and mixed peel, but under 10ppm, so not treated as an allergen
• Egg — used in Bakery 3 to make brioche, in powdered form
• Gluten — found in flour, in every product we make. Controlled with a label declaration
• Soya — found in all our products. Controlled with a label declaration

A label declaration is a statement on the packaging telling customers what allergens are in the product. A label declaration is NOT enough to control sesame or milk (lactose) — those are controlled by allergen control systems.

Goods in, storage and mixing

Know the allergens

If you are not sure whether something contains an allergen, stop and ask your supervisor before you use it.

Sesame seed topped products — Bakery 1

• Sesame seeds are only permitted in the Bakery 1 plant area identified by a red lined area
• Wear the provided allergen clothing — red aprons and red overshoes
• Only the dedicated red cleaning equipment and red utensils may be used in this area
• Sesame is transported in a dedicated locked red container and loaded with a red scoop
• Racks are not permitted inside any red lined area when making sesame products
• Any operative helping to clean, including Hygiene, must also wear the red protective clothing

Sesame seed products in production

End of an allergen production run

• Return the sesame seeds from the hopper to the locked sesame container
• Place any waste seeds into the red waste bin
• Detach the seeding machine from the plant and cover it with the dedicated cover
• Wheel the machine outside the red area for a non-allergen operative to take to the wash room, cleaning up loose seeds
• Open the drawer and clean the drawer plate with the red cleaning utensils and vacuum
• Clean the machine and the area with the red cleaning utensils and vacuum
• Fill out the Allergen Line Cleaning Document
• Remove the red protective clothing into the red rubbish bin
• Place cleaning utensils into the red utensil bin and take them to the cleaning area
• Wash your hands

The Shift Manager/Supervisor must check the area and sign off the cleaning documentation before production returns.

The Allergen Room — Bakery 1 only

The Allergen Room is the dedicated room where we place cheese (after proving) and sesame (before proving) onto the product. Sesame is only used here when the production run is 2 mixes or less.

• Allergens are permitted in this area
• Wear the provided red aprons and red overshoes
• Sanitise your hands on entering, and wash and sanitise them before leaving
• Leftover sesame returns to the lockable seed container; leftover cheese to the dedicated lidded container and back to the fridge
• Waste seeds or cheese go into the red waste bin
• Clean machinery, equipment and the area with the red cleaning utensils and vacuum
• Cheese topped and sesame topped products must ALWAYS be produced at separate times

THIS IS WHERE THE ALLERGEN MATERIALS ARE HANDLED — THE MOST DANGEROUS PROCESS. FOLLOWING THE RULES IN THIS AREA WILL CONTROL THE ALLERGENS.

Cheese slices being added

Cheese handling — close view

Wear the provided red apron and red overshoes whenever handling cheese in the Allergen Room.

Proving, baking, cooling and tipping

Packing, despatch and rework

Trays, cleaning and spillages

Derogation: in an emergency, or where business continuity is threatened, this policy may only be temporarily amended by strict agreement of the Technical Manager and Production Manager, authorised by the Directors.

The movement of racks within the bakery is a fundamental part of the process. Racks, when moved incorrectly, can cause injury. All operatives must be aware that racks are always moving in the bakeries and take care when moving about through them.

You may only move 1 rack at a time, whether full or empty. You must never allow racks to “free-wheel”, or push them and let them go.

Moving more than one rack — Bakery 2 only

You may push up to 4 EMPTY racks at one time between the ovens in Bakery 2 only, and only inside the lined area.

• Line 4 empty racks up at the side of the oven (loading end)
• Hold the first rack with 2 hands
• Make sure that no one is in the area
• Start to push the 4 racks towards the take-off end of the oven
• Walk at a steady pace
• Stop the racks at the line near the end of the oven
• Take one rack at a time to the wall at the end of the oven

Only do this with empty racks — no trays. NEVER push more than 1 rack if the racks have trays inside.

Every employee who uses the changing rooms and/or lockers has a responsibility to look after them.

The rules

• The changing rooms must be kept clean and tidy at all times
• Dirty overalls must be put into the dirty overalls bin
• Shoes must NOT be left underneath lockers — store them in your locker
• Outdoor clothing and food safe clothing must NOT be mixed on the hangers. These are clearly labelled
• NO FOOD is allowed to be consumed in the changing rooms
• NO DRINK is allowed to be consumed in the changing rooms
• You must NOT sit on the floor in your food safe jacket
• You MUST put your hairnet on before your food safe jacket
• You MUST NOT remove your hairnet if your food safe jacket is still being worn
• No strong smelling items (sprays, perfumes) are allowed
• No food or drink is allowed to be stored in your locker
• No glass is allowed to be stored in your locker

The company reserves the right to conduct random audits of lockers and will do so at regular intervals.

Prevent the spread of germs and bacteria — wash your hands properly.

• Wet your hands — use hot or warm water, not cold
• Apply soap
• Scrub your hands for at least 20 seconds — don't forget between your fingers and your fingernails
• Rinse with hot or warm water, not cold
• Sanitise
• Dry with a paper towel or an air dryer, and use the bins provided for your paper towel

Dress for work in this order, every time:

• PUT ON YOUR HAIR NET — if you have a beard or moustache, a snood is required
• PUT ON YOUR TROUSERS
• PUT ON YOUR SAFETY SHOES — ensure they are worn and fastened correctly
• SANITISE YOUR HANDS
• PUT ON YOUR FOOD SAFE COAT

You are being shown and informed of each of the following. Ask about anything you are not sure of before you start work.

• How to lift items properly from the ground
• Not to lift any items which are too heavy or too big for you
• Not to throw dough or any other item within the bakery
• To use the pedestrian walkways whenever possible
• That there are forklift trucks operating in external areas — take care
• Not to work on any machine where a guard is missing
• Where all the emergency stop buttons are and what they do in your working area
• Not to make any amendments, changes or repairs to any plant or equipment
• Not to use ladders unless you have been trained
• That the floor could be slippery — be aware

Health and Safety Awareness

• Not to put your hand into any moving machinery
• Not to clean any plant or equipment unless it is isolated
• To be aware of hot surfaces
• To always wear the correct PPE, correctly
• To check people's safety before starting any machine or equipment
• That it is unsafe to run in the bakery
• Not to climb onto any machinery
• Not to push or pull more than one rack at a time
• Not to push racks and let go while they move
• Not to act unsafely when using dough knives
• Not to climb any racking in stores

Health and Safety Awareness

• Not to drive any FLT without a licence
• Not to remove any panels or guards from machines unless authorised
• Not to open any electrical control panel
• Not to put your hand into any electrical control panel
• Not to bring tools or equipment from home into the bakery
• That horseplay is dangerous and not acceptable
• Where all the fire escapes are
• Where all guards are located in your work area
• Never to climb into the ovens
• Never to carry a knife or any other sharp object on your person
• Who the first aiders are
• To inspect all trays and racks for damage before use
• Where to put any trays or racks that are damaged and require repair

If you hear the fire alarm, stop what you are doing and leave the building straight away by the nearest fire exit.

• Stop work and switch off your machine if it is safe to do so
• Leave by the nearest fire exit — do not go back for belongings
• Walk, do not run, and do not use any lift
• Go straight to your fire assembly point
• Report to the person taking the roll call and stay there
• Do not go back into the building until you are told it is safe

Only tackle a fire with an extinguisher if you have been trained and it is safe to do so. Raise the alarm first.

Where to assemble

Wait at your assembly point until you are counted and told it is safe to return. If you are working in a different building that day, use that building's assembly point.