While the FDA does not currently have any standard set rules to follow when it comes to implementing a color-coding program, there are some common best practices that you can follow to get the most out of color-coding the facility.
Here are some ideas to help you design an effective color-coding program:
Keep your color-coding system simple– Limiting the number of colors you use will go a long way in simplifying the process. Too many times, people get bogged down with the idea that every line and every single process has to have a different color. This is not the case. Try to have a different color only when cross-contamination is a concern at a critical control point in the process. Those points where control is not needed could potentially use the same color, since cross-contamination is not a threat. The more colors in the mix, the more confusing it becomes, and the less effective it will be.
Pick logical colors for each area-Making the transition to a color-coding system needs to be as seamless as possible. In order to keep confusion low, when stepping into this system, try to pick colors that make the most sense in each area. For example, certain colors might make sense for certain areas in your food processing facility, such as red for raw meat, or yellow for wheat. Do what is most logical for your facility. Also, make sure that it makes sense to both managers and employees. If everyone is on the same page, the transition will run more smoothly.
Avoid complicated color assignments-Having customized tools, like a different colored handle than the broom, might seem like a great idea to help differentiate zones. However, it does lead to confusion. If you mix and match handles and brushes the end result might be chaos. Say you have a red broom with a green handle (Merry Christmas?). Now, you have the problem of trying to figure out if it goes in the green zone or the red zone. Save everyone the confusion, and stick to one color per zone. Instant recognition is the key to keeping confusion to a minimum. You should be able to look quickly and determine which zone is which.
Roll out the color-coding program all at one time– This goes back to avoiding confusion. If you try to incorporate the new system in with the old one, people are just going to be confused. It’s best to start the program all at once. It might be more difficult in the beginning, but it will be worth it in the end. Also, having a definite end date to the old program and a definite start date for the new system will make the transition even smoother.
Good communication is key– Having everyone on the same page will help with starting your color-coding program. A good practice is to first discuss the changes with shift managers, then roll it out to the employees. The mangers should have a good understand of the new system so they can address any questions or concerns the employees might have. Offering a cheat sheet to employees that explains the color zones will be tremendously helpful in overall adoption of the program.
Reinforce the color-coding with good signage-When starting a color-coding program, you don’t want any ambiguity in how it’s perceived. Make it absolutely clear what the program is, and when it is starting. The best thing to do is label every point in the process, in multiple languages if necessary.
Be sure your tools and storage areas match– Be sure the tools are stored in the same area where they are used to avoid confusion, cross-contamination, and equipment loss. If the red tools are stored on a red bracket or red shelf, it is easy to see exactly where that tool should go when it isn’t in use. Having an organized storage area will be very helpful in maintaining the integrity of the color-coding system.
Follow through– Utilize the same documentation at point of use, with the purchasing department and with the quality manager so everyone is on the same page. Making sure all loose ends are tied up will help exponentially to the success of the color-coding program. If the program is successful, your facility will be much safer.