Essential to an effective color-coding system is a well thought-through communication plan. With the proper communication channels in place, your color-coding system has the best chance for successful adoption—in turn helping you to mitigate the risk of cross-contamination. Communication should start at the top of the company, and go down to each and every employee. When all employees are knowledgeable about the new or changed program, the chances of success are even higher.
The initial employee training communications must be clear and concise to ensure everyone is on the same page. When starting, or even revising, a color-coding system, employees must understand the reason for the change. Dealing with the threat of cross-contamination is serious, and the need to establish barriers to those threats is critical. The better every employee understands this, the more effective the color-coding system will be when put into practice.
Communicating with employees on how color-coding can help with tool storage is also very important. Establishing procedures for storage can help with tool inventory management. If employees are taught the proper procedures for tool storage right out of the gate, this will go a long way in preventing any loss of tools or time. One particular way to help encourage proper storage is to use custom shadow boards that integrate outlines of the tools so that there is no question where tools belong. Some facilities might use the 5S system to maximize organization. The use of color-coding is a great way to enhance the 5S philosophy. 5S is a Japanese workplace organizational system which uses five phases: sort, set in order, systematic cleaning (or shine), standardize and sustain. Along with using shadow boards, 5S helps encourage employees to properly store tools, maximizing their usable life.
Daily communication to employees is essential to the longevity of the program. Daily communication starts with good signage. Clearly written instructions, bilingual if necessary, are essential to providing employees with instructions on the color-coding program. It may even help to include visual or graphic representations on the signage for each zone; for example, a picture of a peanut on the sign designating the color of tools intended for use with peanuts. In addition to written instructions, daily verbal communication is also vital. Any changes or revisions to the color-coding plan must be clearly communicated to all employees, from the top down.
It is a best practice to include your color-coding program in your official regulatory documentation. Many regulatory bodies require documentation of certain procedures, and color-coding can become a great advantage for your operation. While color-coding is not required for compliance with any food safety regulations, it is looked upon with favor by auditors. Including your color-coding plan in the facility’s Preventive Control or Prerequisite Procedures, which includes GMPs, SOPs, CCPs, and Non-CCPs, will go a long way in ensuring company-wide adoption, consistency, and compliance of the program. For facilities that must comply with HACCP or HARPC regulations, including color-coding on those plans is, again, not required but, a best practice. HACCP, or Hazard Analysis & Critical Control Points, is a food safety management system which helps to identify and control cross-contamination threats. Similarly, HARPC, also known as Hazard Analysis and Risk-Based Preventive Controls, also requires identification and control of risks in food processing facilities.
Here are some important things to remember:
- Start at the top and go down
- Communicate with all levels of employees to ensure complete implementation
- Have good signage
- Signs should have written and visual cues to identify the zone and where the tools are approved for use
- Include a printout that gives details for reordering of tools, such as vendor, item number, manufacturer, etc.
- Keep up with training
- Consistent training programs for all employees will improve adoption and ongoing use of the program
- Include color-coding on regulatory plans
- Color-coding is looked upon favorably by regulatory bodies