Course Catalog with Course Titles and Competencies 09/27/17
Alchemy Course Titles & Competencies Tyson Compliance Orientation Training... 8 2 Drug and Alcohol Orientation... 8 Code of Conduct Orientation... 8 Core Safety Mandates Orientation... 8 Harassment and Discrimination Orientation... 9 Tyson Compliance Mandated Training... 9 Code of Conduct Annual Course... 9 Tyson Job Roles... 9 Pump Operator... 9 Post Pump Scale Operator... 10 Whizard Knife Operator... 10 Trimmer... 10 Styler... 10 Case Sealer Operator... 11 Palletizers (Stack Boxes)... 11 Ross 3320 Operator... 11 Pack-Box Product... 12 Janitor... 12 Trimming... 12 Meat Styling... 12 Tray Rework... 12 Overwrap Packaging... 13 Knife Safety... 13 Knife Maintenance... 13 Gold Hat Expectations... 13 Gold Hat Warning Procedure... 14 Mondini Operator... 14 Weigh/Price Labeler Operator... 14 Initial Grinder Operator... 15 Mule Operator... 15 Lift Truck Operator... 15
Picker... 15 Heat Press Overview... 16 Heat Press Troubleshooting... 16 Tyson Safety Awareness... 16 Emergency Preparedness... 16 Medical Services and First Aid... 16 Bloodborne Pathogens... 16 Slips, Trips, and Falls... 17 Powered Industrial Trucks... 17 Personal Protective Equipment (PPE)... 17 Confined Spaces... 17 Lock Out/Tag Out... 17 Machine Guarding... 17 Hand and Power Tools... 18 Ergonomics... 18 Safe Lifting... 18 Workplace Violence... 18 Management Training... 18 Worksafe 1... 18 Worksafe 2... 19 Worksafe 3... 19 Tyson Environmental Awareness... 19 Environmental Awareness... 19 Hillshire Custom... 19 Food Safety 101... 19 SQF and Food Safety... 20 Hand Washing... 20 Documenting and Record Keeping... 20 Introduction to Lean... 21 Daily Lean Management System Overview... 21 Sensory Evaluation in Product Testing... 21 Cobb-Vantress Custom... 22 Poultry Diseases of Importance... 22 Rules and Procedures for Outside Bird Contact... 22 3
4 Proper Farm, House, and Hatchery Entry... 22 Pest Control at Cobb Facilities... 22 Food Safety... 23 Cleaning and Sanitizing... 23 Cleaning and Sanitizing Procedures for Food Manufacturers... 23 Cleaning and Sanitizing in a Dry Foods Facility... 23 Introduction to CIP... 23 Food Allergens... 24 Introduction to Food Allergens... 24 Introduction to Food Allergens - Refresher... 24 Proper Handling of Food Allergens... 24 Proper Handling of Food Allergens - Refresher... 25 Dangerous Microorganisms... 25 Controlling Salmonella in Food Manufacturing... 25 Controlling Salmonella and Campylobacter in Poultry Processing... 25 Dangerous Microorganisms in Food Manufacturing (Fahrenheit)... 26 Preventing Foodborne Illness... 26 Understanding Listeria and its Dangers to Food... 26 Bacteria Basics... 27 Good Manufacturing Practices... 27 GMPs: Effective Hand Washing Techniques... 27 GMPs: Effective Hand Washing Techniques - Refresher... 27 GMPs: Promoting Personal Hygiene... 28 GMPs: Promoting Personal Hygiene - Refresher... 28 Preventing Food Contamination... 28 Preventing Food Contamination - Poultry... 29 Preventing Food Contamination - Frozen Foods... 29 Air Hose Safety... 29 Water Hose Safety... 30 Programs and Standards... 30 Basic Food Facility Defense... 30 Overview of HACCP... 30 Overview of HACCP - Refresher... 31 Overview of HACCP - Poultry... 31 Overview of HACCP for Supervisors... 31 Effective Pest Control Practices... 32 Overview of Preventive Controls... 32
Introduction to Food Fraud... 32 Workplace Safety... 33 Bloodborne Pathogens... 33 Ammonia Awareness... 33 Ammonia Accident Prevention and First Aid... 33 Asbestos Awareness... 34 Back Injury Prevention... 34 Basic First Aid... 34 Combustible Dust... 35 Confined Spaces for Affected Employees... 35 Confined Spaces for Attendants... 35 Electrical Safety... 36 Emergency Preparedness... 36 Ergonomics... 36 Heat Exhaustion... 37 Introduction to Fire Extinguishers... 37 Introduction to Respirators... 37 Fire Prevention and Protection... 38 Lift Truck Safety Awareness... 38 Lift Truck Safety Awareness - Refresher... 38 Hand and Power Tools... 38 Introduction to Hazard Communication... 39 GHS Hazard Communication: Pictograms and Hazards... 39 GHS Hazard Communication: Pictograms and Hazards - Refresher... 39 GHS Hazard Communication: Standard Labels... 39 GHS Hazard Communication: Standard Labels - Refresher... 40 GHS Hazard Communication: Safety Data Sheets... 40 GHS Hazard Communication: Safety Data Sheets - Refresher... 40 Hearing Protection... 41 Lockout / Tagout Procedures... 41 Lock Out / Tag Out Procedures - Refresher... 41 Machine Guarding... 42 Personal Protective Equipment (PPE)... 42 Slips, Trips, and Falls... 42 Slips Trips and Falls - Refresher... 43 Working at Height... 43 Knife Safety Basics (Product Knives)... 43 5
Animal Welfare... 44 Beef... 44 6 Unloading and Receiving Cattle at Processing Facilities... 44 Proper Handling and Movement of Cattle... 44 Humane Stunning Practices for Cattle... 44 Pork... 45 Unloading and Receiving Pigs at Processing Facilities... 45 Proper Handling and Movement of Pigs... 45 Humane Stunning Practices for Pigs... 45 Poultry... 45 Introduction to Hatchery Operations... 45 Proper Catching and Handling Methods... 46 Humane Euthanizing Practices for Poultry... 46 Poultry Welfare During Transportation and Receiving... 46 Humane Practices for Live Bird Processing... 46 Warehouse... 46 Lift Truck Operator Overview... 46 Pallet Truck Review... 46 High Lift Truck Review... 47 Slips, Trips, and Falls - Distribution... 47 Material Handling - Distribution... 47 GMPs: Personal Hygiene - Distribution... 48 Basic Food Defense Distribution... 48 Maintaining the Cold Chain... 48 Food Safety SOPs - Pre-load Temperature Checks... 48 Food Safety for Selectors - Overview... 49 Driver Food Safety SOPs - Trailer Maintenance... 49 Driver Food Safety SOPs - Pre-chilling Procedures... 49 Driver Food Safety SOPs - Maintaining Proper Temperature... 49 Driver Food Safety SOPs - LTL Delivery Stops... 49 Basic Food Defense for Drivers... 50 Supervisor Training... 50 Career Advancement... 50 Being a Successful Supervisor... 50 Communicating Effectively in the Workplace... 50 Solving Problems at Work... 51
Effective Supervision... 51 Communication and Trust... 51 Motivation, Discipline and Goals... 51 Patience, Consistency and Getting the Job Done... 52 Coaching and Observing... 52 Implementing Coaching and Observations... 52 Exploring the Roles and Behaviors of a Coach... 52 Life Skills Training... 53 Life Skills... 53 Appropriate Workplace Behavior... 53 Social Skills in the Workplace... 53 Anger Management... 53 Avoiding Destructive Behavior... 54 Housing... 54 Nutrition and Physical Fitness... 54 Transportation... 55 Financial Literacy... 55 Living on a Budget... 55 Making the Most of Your Money... 55 Problems with Credit... 56 Alchemy Resources... 56 Group Training: Learner Basics (IR Remotes)... 56 Group Training: Learner Basics (RF Remotes)... 56 Operations... 57 GLPs: Overview of Good Laboratory Practices... 57 Introduction to Root Cause Analysis... 57 Lean Manufacturing... 57 7
NOTE: Course time indicated is an "estimate" for a single user to complete a course in mouse mode with one feedback loop shown per question. The actual time necessary to complete a training course will vary dramatically due to numerous factors including: Type of computer used Type of remote used for training Number of users viewing the course Number of feedback loops and remediation questions viewed Length of time for users to respond to questions Tyson Compliance Orientation Training Drug and Alcohol Orientation Estimated Course Time - 18 minutes Discuss the purpose of Tyson's Drug and Alcohol Abuse Policy and the behavior it prohibits. Identify the times when a Team Member may be screened. Discuss the actions that will occur if substance abuse is identified. Discuss the rules regarding prescribed medications. Code of Conduct Orientation Estimated Course Time - 28 minutes Identify the cornerstones of our Culture of Doing What's Right. Discuss how the Code of Conduct applies to Team Member safety. Discuss how the Code of Conduct applies to food safety. Discuss how the Code of Conduct applies to conflicts of interest. Discuss how the Code of Conduct applies to theft of time and property. Discuss how the Code of Conduct applies when dealing with governmental personnel or union officials. Core Safety Mandates Orientation Estimated Course Time - 19 minutes Understand the purpose of the Tyson Core Safety Mandates and what will happen if a mandate is violated. Discuss the Tyson Core Safety Mandates regarding Lockout/Tagout. Discuss the Tyson Core Safety Mandates regarding Permit Required Confined Spaces. Discuss the Tyson Core Safety Mandates regarding Fall Prevention and Protection. 8
Harassment and Discrimination Orientation Estimated Course Time - 15 minutes Discuss the purpose of Tyson's Harassment and Discrimination Policy. Identify the types of behavior that are prohibited. Demonstrate the actions a Team Member must take if aware of harassment or discrimination. Discuss the actions Tyson will take in response to a report of harassment or discrimination. Define retaliation and discuss the consequences for retaliating against an individual. Tyson Compliance Mandated Training Code of Conduct Annual Course Estimated Course Time - 24 minutes Identify the cornerstones of our Culture of Doing What's Right. Discuss how the Code of Conduct applies to Core Safety Mandates. Discuss how the Code of Conduct applies to the Drug and Alchohol Policy. Discuss how the Code of Conduct applies to the Harassement and Discrimination Policy. Tyson Job Roles Pump Operator Estimated Course Time - 10 minutes Consistency is very important. Never operate without certification. You should know all machine functions. You must be able to set up the machine for production and verify proper injection. Always perform a piece test As you feed product into the pump, keep track of product flow and combo labels. Take note of all combo weights and record all pump gains. Report all paper work at the end of the shift. 9
Post Pump Scale Operator Estimated Course Time - 10 minutes Make sure the scale has been cleared before you begin running a new combo. Be sure to weigh every single piece of product before transferring it on to the conveyor. Make sure that the scale is printing the weight of each piece you pass over it. Never weigh product while your hand is resting on the scale. This will make the reading inaccurate. Remember to record the weights at the end of each combo. After you have recorded the weights, remember to clear the scale after each combo. Whizard Knife Operator Estimated Course Time - 8 minutes Know all the product specifications in your department. That you must be certified on Whizard knife sharpening. To trim primal to it's specifications. Never use a dull blade. Never over trim primal. Trim off fat, glands, inspection ink, pasteurization, discoloration, etc. Check for defects. Trimmer Estimated Course Time - 9 minutes Why you must use proper PPE. The proper order and procedures for putting on the Personal Protective Equipment. How to visually inspect the product to make sure it meets specifications. How to pull product that does not meet specifications. How to trim product to specifications as need. What to do with the product after it's been re-trimmed. Styler Estimated Course Time - 8 minutes Know all the product specifications in your department. Follow styler procedure. Use the correct tray size and properly labeled tray Always use tray covers. Always arrange product in tray according to product specifications Always fill tray 3/4 full. Check for defects. Never throw tray onto the conveyor. 10
Case Sealer Operator Estimated Course Time - 11 minutes How to lock and unlock the machine according to proper Lockout/Tagout procedures. How to check that the Stop, Start, and Interlock buttons all work. How to check the photo eye to make sure it's working. How to test the machine to see if it runs. How to maintain box integrity as the boxes move down the line. What to do with damaged boxes and boxes with label defects. The proper procedure for changing the tape in the Case Sealer. Palletizers (Stack Boxes) Estimated Course Time - 10 minutes You should always have a copy of the production schedule. Make sure the empty pallets are lined up at the end of the conveyor line for the beginning of your shift. Always grab both sides of the box when moving it, not just one side. Always carry the boxes horizontally and never tilted. Never throw a box. Always stack it carefully and neatly on the pallet. When stacking the boxes on a pallet make sure all the box labels are facing out. Keep an accurate count of all the boxes that are placed on a pallet. Remove pallets that are full and replace them with empty ones. Ross 3320 Operator Estimated Course Time - 14 minutes Anyone who operates a Ross 3320 must have the proper training and certification. Never try to operate this equipment unless you know how it functions and how to identify potential problems. Be sure to set the Weigh/Price Labeler at the start of the production run to be sure the conveyor is running properly, the labels are correct and the trays are being sealed properly. When the labels are printing correctly, clear the tray count from the previous day's production and have your paperwork reviewed by a Supervisor and Quality Assurance before you begin running any new product. Never try to put a damaged tray through the machine. Make sure any tray that is leaking or has a low dome is re-trayed, re-labeled and re-sealed. Never remove any safety guards from the machine, put your hands in the machine while it's running or try to clear a jammed tray unless the machine has been locked out. 11
Pack-Box Product Estimated Course Time - 13 minutes Which packaging materials to use for each product. Where each label is supposed to go and how it should look. How to check the seal area of each tray for debris. How to handle the trays and place packages into the boxes How and where to ID stamp the boxes. How to place the cases onto the conveyor belt. Janitor Estimated Course Time - 10 minutes Color coded tools are very important and identify what type of trash is being disposed of. That yellow barrels are for inedible product only. That gray barrels are for used trays and other trash. Cardboard must be recycled in the recycling compactor or the general disposal compactor. Never place any of your body parts in the trash compactor. That you must stack cardboard neatly so it can be easily moved by the pallet jack. How to empty inedible barrels into designated combo/pallets and the proper procedure for labeling. The process for emptying gray barrels into bins, then into compactors for disposal. Trimming Estimated Course Time - 10 minutes The importance of trimming to Tyson and to our customers. The three basic knives used for trimming. The different jobs trimmers have. How trimming affects the Tyson brand. Meat Styling Estimated Course Time - 9 minutes Define the term "styling" and understand the importance of styling to Tyson and to customers. Explain why different sized trays are used. Identify the four basic styling methods and when to use them. Tray Rework Estimated Course Time - 12 minutes Identify the most common types of rework. Use the correct terminology for classifying the cause of rework. 12
Overwrap Packaging Estimated Course Time - 14 minutes Discuss the job functions of the Line Feeder. Discuss the job functions of the Ulma Operator. Discuss the job functions of the Marel Operator. Discuss the job functions of the Mother Bagger. Discuss the job functions of the M Tec Operator. Knife Safety Estimated Course Time - 10 minutes Cutting techniques that will help you avoid injury and soreness. Proper knife handling. Key rules for preventing hazards. How to keep your work environment safe and your equipment clean. Knife Maintenance Estimated Course Time - 14 minutes The importance of a sharp knife. The various knives used in your workplace which include skinning, boning, trimming, breaking, and Whizard knives. Types of potential damage to the blade edge and what might cause the damage. Procedures for repairing the knife's edge, sharpening, or steeling. The proper procedures for safely steeling a knife. Gold Hat Expectations Estimated Course Time - 10 minutes Follow all the attendance policies that are in effect for the management support team. Fill out the Product Inspector Line Log to keep track of any time you spend away from the line during production. Have the specification books with you at all times. Know the specifications for the products. Always follow the Gold Hat Warning Procedure. If you find an issue with the product on the production lines, tell a supervisor or the appropriate production team members. If you find a safety or sanitation issue always notify Quality Assurance Management. Always follow the Good Manufacturing Practices that are in effect. Attend the monthly safety and Brand Zone meetings. Treat other team members with dignity and respect. 13
Gold Hat Warning Procedure Estimated Course Time - 10 minutes That it is a system used to communicate quality problems. That the line can be put in warning and the circumstances when that can occur. That the line can be shut down and the circumstances when that can occur. Procedures for resumption of normal line speeds from both the warning and the shut down. That a line can be shut down if food safety is compromised. That corrective action occurs when the lead person or the supervisor corrects the problem at hand. That all warnings and shut downs must be properly documented by the Gold Hats in the daily paperwork. Mondini Operator Estimated Course Time - 16 minutes Make sure you set up the Mondini/Risco machines using only the designated parts for each machine. Always use two people when installing or replacing the roll of film on the machine. Fill the Denester to the top level with trays. Set the controls on the Risco/Mondini to the start settings to get the best possible loaf and seal right from the start of production. Talk with the Blender Operator to find out the type and grade of product you will be running and tell that information to the Weigh/Price Labeler operator. Start the system as soon as all the components are ready to create a loaf on the conveyor. Adjust the Denester and the timing, so the loaf is placed in the tray properly. Always monitor the Denester, the film roll and the metal detector during production. Talk to your supervisor so you can set the proper production rate on the machine. Always fill out your paperwork and "down time" log completely and accurately. Weigh/Price Labeler Operator Estimated Course Time - 14 minutes How to check the Weigh/Price Labeler conveyor. How to select a test tray. How to run the test tray though the Weigh/Price Labeler machine. How to adjust the Weigh/Price Labeler for proper label placement. How to clear the tray count from the prior day's production. What information should be on a label. What are the proper forms that need to be completed during the operational phase. 14
Initial Grinder Operator Estimated Course Time - 12 minutes Consistency is very important. Never operate without following proper Lockout/Tagout procedures. You should know all machine functions. You must be able to set up the machine for production and check meat labels. Always wrap combos securely. Transfer the mix, throwing out the first portion of meat. Make sure the herbalox dispenser is running when grinding meat. Disassemble grinder for inspection and document findings on the Tear Down Form. Assist with the clean up of the area. Report all paper work at the end of the shift. Mule Operator Estimated Course Time - 11 minutes Never operate without certification. You must inspect your mule before using it. Always make sure you are wearing your Personal Protective Equipment. You must receive direction from management to know what product to run. Always transfer totes and combos over to the weigh scale first, then over to the lines for production. Keep track of partial combos and return them to the coolers. Keep up with line production. Lift Truck Operator Estimated Course Time - 13 minutes How to perform a pre-shift visual and operational inspection of the fork lift truck. Why you should wear proper PPE at all times. How to log onto the RF unit, following the proper procedures for each lift job. How to use the LPN label and the RF unit to locate proper inventory placement. How to follow all procedures for scanning the barcode or entering the stage number. How to keep an accurate inventory of our products. How to maintain customer satisfaction. Picker Estimated Course Time - 8 minutes You must fill out a pre-shift inspection sheet. You must wear proper PPE when doing visual inspections of the lift trucks. You must log into the system using the RF unit. You will receive further training on the RF unit from a trainer/supervisor. Get an order number from the load controller, type it into the RF and scan one LPN label. After locating the cases to be shipped, enter the stage number into the system. 15
Heat Press Overview Estimated Course Time - 13 minutes Describe the purpose and operation of the Blender/Hopper. Describe the purpose and operation of the Divider/Rounder and Proofer. Describe the purpose and operation of the Pre-press/Press. Describe the purpose and operation of the Oven. Describe the packaging process. Heat Press Troubleshooting Estimated Course Time - 15 minutes Identify the places in the Heat Press production line where products may fold and discuss how to troubleshoot the problem. Identify the reasons why edge defects may occur and discuss how to troubleshoot the problem. Identify the reasons why products may be produced at different sizes and discuss how to troubleshoot the problem. Tyson Safety Awareness Emergency Preparedness Estimated Course Time - 10 minutes Describe what the Emergency Action Plan consists of. Identify the goals of the Emergency Action Plan. Explain the importance of being alert, informed, and prepared. Medical Services and First Aid Estimated Course Time - 11 minutes Recognize whom to contact for help if injured. Identify the location of first-aid equipment and supplies. List the health care procedures for treating workplace illnesses and/or injuries. Understand record keeping procedures, your rights and how they are used. Bloodborne Pathogens Estimated Course Time - 10 minutes Describe what bloodborne pathogens are. Explain what a written exposure control plan consists of. Identify who can administer first aid and CPR. 16
Slips, Trips, and Falls Estimated Course Time - 18 minutes Explain how to prevent slips, trips, and falls. List the key points to ladder safety. Recognize the importance of good shoes. Powered Industrial Trucks Estimated Course Time - 15 minutes Identify who can operate a powered industrial truck. Describe what to do before operating a powered industrial truck. List the proper procedures for operating a powered industrial truck. Personal Protective Equipment (PPE) Estimated Course Time - 16 minutes Explain why personal protective equipment is required and what types are commonly used. Describe the importance of hearing protection, how it's used, testing procedures and your responsibilities. Confined Spaces Estimated Course Time - 12 minutes Explain what a confined space is. Identify who can enter a confined space. List the proper procedures for entering a confined space. Lock Out/Tag Out Estimated Course Time - 13 minutes Define what Lockout/Tagout applies to. Describe what an energy-isolating device is. Recognize when to perform Lockout/Tagout. Identify who is authorized to perform Lockout/Tagout. Machine Guarding Estimated Course Time - 18 minutes Describe what guards are designed to do. List the types of guards used. Explain the important safety issues when working around machinery. Recognize the importance of keeping your mind on your work and your eyes on the target. 17
Hand and Power Tools Estimated Course Time - 15 minutes Recognize the hazard of different types of hand and portable power tools. List some common hand and power tools. Understand the proper handling and care of hand portable power tools. Ergonomics Estimated Course Time - 20 minutes Describe what MSD's are. Explain what ergonomics are. Define the ergonomic process. Understand the potential risk factors of MSD's. List the types and importance of job improvements. Safe Lifting Estimated Course Time - 12 minutes Understand how to strengthen and protect your back, both on and off the job. List the proper lifting techniques. Explain the importance of a healthy back. Workplace Violence Estimated Course Time - 13 minutes Define what workplace violence is. Describe how you can help prevent workplace violence. List what you can do to reduce the risk of becoming a victim. Explain what the best self-defense is if you become a victim. Management Training Worksafe 1 Estimated Course Time - 21 minutes Define the terms "musculoskeletal disorders" and "ergonomics," and understand the relationship between these two terms. Discuss the purpose of the Tyson Fresh Meats Ergonomics Program and identity its six elements. Discuss the role and responsibility of upper management. Discuss the role and responsibility of plant management. Discuss the role and responsibility of health and human services. Discuss the role and responsibility of employee management. Discuss the role and responsibility of the employee. 18
Worksafe 2 Estimated Course Time - 15 minutes Discuss how MSDs affect the body. Distinguish between workplace illnesses that are considered MSDs and injuries that are not considered MSDs. Discuss how environmental conditions can contribute to the development of MSDs in the workplace. Identify job tasks that can contribute to the development of MSDs in the workplace. Discuss how tools and equipment can contribute to the development of MSDs in the workplace. Worksafe 3 Estimated Course Time - 19 minutes Identify personal factors that can contribute to the development of MSDs in the workplace. Discuss good practices to limit a workers chance of developing a MSD. Identify the range of motion to which a worker should limit their movement when working. Identify the physical signs to look for that indicate an employee may be developing a MSD. Demonstrate the actions a supervisor should take if they observe potential ergonomic problems. Discuss the purpose of the Restricted Duty Program. Identify the 5 How's of Prevention Management. Tyson Environmental Awareness Environmental Awareness Estimated Course Time - 16 minutes Understand the importance of Tyson's Environmental Commitment. Discuss the focus of Tyson's Environmental Commitment. Identify environmental situations for which you should inform your supervisor. Identify the actions that Tyson Team Members can take to promote environmental responsibility. Hillshire Custom Food Safety 101 Estimated Course Time - 19 minutes Understand the purpose of HACCP, and why it is important to Hillshire Brands. Identify the types of hazards that HACCP aims to reduce or eliminate. Describe the types of pre-requisite programs in place that promote food safety. Understand how Food Safety Systems are developed. Understand the importance of good documentation. 19
SQF and Food Safety Estimated Course Time - 19 minutes Understand the purpose and importance of SQF. Understand why SQF is important to Hillshire Brands. Discuss how food safety systems and quality management processes ensure food safety. Explain how food safety guidelines apply to your job. Explain how quality guidelines apply to your job. Identify the areas of a facility that an auditor inspects. Demonstrate how to respond if you interact with an SQF auditor. Hand Washing Estimated Course Time - 20 minutes Understand the importance of washing hands. Discuss the importance of maintaining personal hygiene. Identify the times when you should wash your hands. Explain when to wash your hands as part of the process of putting on PPE. Identify the necessary components of a hand washing station. Demonstrate the hand washing process. Demonstrate the proper use of gloves. Identify the times when gloves should be changed. Documenting and Record Keeping Estimated Course Time - 16 minutes Understand the importance of good documentation. Discuss the requirements for completing documentation. Demonstrate how to properly complete a form. Explain how to make corrections to a form. Discuss what to do when turning in records. Understand how records are reviewed 20
Introduction to Lean Estimated Course Time - 25 minutes Waste, which we can define as the use of resources beyond what is necessary to meet customers needs, can plague any production or operational environment if it is not recognized and purposefully reduced. The concept of Lean is the relentless pursuit of waste elimination. This introductory course exposes the learner to the basic principles of Lean, value as a concept and further details types of waste that can be found in the work environment. Finally, the course offers five principles in reducing waste in a Lean environment. Apply the basic definitions of Lean and value to identify activities that are value-added and non-value added. Identify activities that are non-essential non-value added and should thus be eliminated. Identify a variety of wasteful activities in the work environment, whether that is in manufacturing production or the support/enabling functional groups of the office. Discuss the key principles of Lean for reducing waste. Daily Lean Management System Overview Estimated Course Time - 35 minutes In the relentless pursuit of waste elimination, we need tools and systems to ensure that we are able to make an impact on goals every day. This is the foundation of the Daily Lean Management System. The DLMS Overview breaks down the pursuit of waste elimination into manageable goals with progress to be measured and discussed every day. Recognize the purpose and benefits of the Daily Lean Management System. Understand the purpose and structure of the Primary Visual Display. Describe how to conduct short interval coaching dialogue. Describe how to assess the health of the DLMS. Sensory Evaluation in Product Testing Estimated Course Time - 23 minutes Tyson Foods strives to maintain an impeccably high level of quality across all of our product brands. One way we accomplish this is through a stringent sensory evaluation process, which involves using your senses to evaluate a product. In this course, we ll describe the process of sensory evaluation, as well as provide examples of the sensory traits deemed most acceptable by our customer base. Define the concept of flavor. Identify an example of an attribute of products in meat/savory product lines. Identify an example of an attribute of products in sweet product lines. Recognize an attribute of a product that has experienced quality degradation. Describe best practices to follow when product testing. Be aware of possible changes to production that may alter the outcome of an evaluation. 21
Cobb-Vantress Custom Poultry Diseases of Importance Estimated Course Time - 22 minutes Understand the goal of biosecurity, and why we must be diligent in promoting biosecurity. Identify common types of bacterial diseases that affect birds, and describe the dangers of these diseases. Identify common types of viral diseases that affect birds, and describe the dangers of these diseases. Recognize symptoms of disease in a flock, and how you can personally help prevent the spread of disease. Rules and Procedures for Outside Bird Contact Estimated Course Time - 23 minutes Explain why bird contact rules are important for promoting biosecurity and reducing the spread of disease. Identify and describe different types of bird contact. Understand the consequences of direct bird contact and the 72 hour rule. Explain specific procedures for typical bird contact situations. Describe the procedures for wild bird nest removal from a Cobb facility. Proper Farm, House, and Hatchery Entry Estimated Course Time - 23 minutes Understand the importance of proper facility entry procedures, and explain the difference between the clean side and dirty side. Describe the critical pre-entry procedures for entering a facility. Explain the appropriate way to enter a facility containing a flock. Discuss the procedures that must be followed when bringing supplies, equipment, and outside vehicles into a facility. Pest Control at Cobb Facilities Estimated Course Time - 26 minutes Explain why pest control is an important part of maintaining biosecurity. Describe proper rodent and vermin control procedures. Understand and describe the insecticide program for insect control. Explain specific procedures for fly control and beetle control. Explain how to control wild birds from contaminating our flocks, and how to remove a wild bird nest from a facility. 22
Food Safety Cleaning and Sanitizing Cleaning and Sanitizing Procedures for Food Manufacturers Estimated Course Time - 22 minutes A thorough cleaning and sanitizing process will effectively remove visible dirt and reduces microorganisms to safe levels. This course outlines a basic cleaning process for maintaining a wet facility, and discusses the characteristics of a growth niche and biofilm. It also stresses the importance of handling chemicals properly and wearing personal protective equipment. Explain the difference between cleaning and sanitizing. Recognize the importance of proper handling of chemicals. Outline a basic cleaning process for effectively maintaining a facility. Recognize the importance of addressing growth niches and biofilms as part of a regular cleaning and sanitizing schedule. Cleaning and Sanitizing in a Dry Foods Facility Estimated Course Time - 21 minutes A thorough cleaning and sanitizing process will effectively remove visible dirt and reduces microorganisms to safe levels. This course outlines a basic cleaning process for maintaining a dry facility, and discusses the characteristics of a growth niche and biofilm. It also introduces good practices for cleaning equipment when water is necessary. Explain the difference between cleaning and sanitizing. Describe the characteristics of a growth niche and biofilm. Identify tools commonly used for cleaning in a dry facility. Outline a basic cleaning process for effectively maintaining a dry facility. Describe how to clean mobile equipment when water is necessary. Discuss good practices for cleaning stationary equipment when water is necessary. Introduction to CIP Estimated Course Time - 14 minutes Following a production run or during a changeover, complex closed systems are most often cleaned using automated clean-in-place systems, or CIP systems. This course introduces the purpose of a CIP system, and some of the factors that influence the effectiveness of a CIP process. Describe the purpose of a CIP process Recognize that various factors may be adjusted as part of a CIP process 23
Food Allergens Introduction to Food Allergens Estimated Course Time - 17 minutes Food processors may handle many different food products each day. However, some foods can be dangerous if a person is allergic to an ingredient in the food. This course identifies the most common food allergens, and explains why it's so important to properly handle and label foods that contain allergens. Recognize the seriousness of an allergic reaction, and the need for a person with a food allergy to avoid certain foods. Understand why it's so important to properly label foods that contain allergenic ingredients. Identify examples of the types of places in which cross contact can occur. Introduction to Food Allergens - Refresher Estimated Course Time - 7 minutes Food processors may handle many different food products each day. However, some foods can be dangerous if a person is allergic to an ingredient in the food. This course identifies the most common food allergens, and explains why it's so important to properly handle and label foods that contain allergens. Recognize the seriousness of an allergic reaction, and the need for a person with a food allergy to avoid certain foods. Understand why it's so important to properly label foods that contain allergenic ingredients. Identify examples of the types of places in which cross contact can occur. Proper Handling of Food Allergens Estimated Course Time - 18 minutes Cross contact occurs when allergens are mixed into products that shouldn't have them. To prevent this from occurring, food processors must work hard to prevent cross contact in all areas of production. This course explains how cross contact can happen when ingredients are received, stored, formulated, and processed. It also discusses how to prevent cross contact from happening. Recognize that "cross contact" occurs when allergens are mixed into products that shouldn t have them. Understand that shipments must be verified upon arrival and stored appropriately. Understand the need to prevent cross contact during formulation. Recognize the importance of proper labeling and packaging. Understand that proper cleaning and sanitation can help control the spread of allergens. 24
Proper Handling of Food Allergens - Refresher Estimated Course Time - 9 minutes Cross contact occurs when allergens are mixed into products that shouldn't have them. To prevent this from occurring, food processors must work hard to prevent cross contact in all areas of production. This course explains how cross contact can happen when ingredients are received, stored, formulated, and processed. It also discusses how to prevent cross contact from happening. Recognize that "cross contact" occurs when allergens are mixed into products that shouldn t have them. Understand that shipments must be verified upon arrival and stored appropriately. Understand the need to prevent cross contact during formulation. Recognize the importance of proper labeling and packaging. Understand that proper cleaning and sanitation can help control the spread of allergens. Dangerous Microorganisms Controlling Salmonella in Food Manufacturing Estimated Course Time - 19 minutes Salmonella is a type of bacteria that is commonly present in the digestive tract of many animals, and the food that animals provide. This course explains how bacteria can enter and spread around a facility, and describes how to help prevent contamination through proper sanitation and good manufacturing practices. Describe what Salmonella is and where it can survive. Explain how Salmonella can enter a facility. Explain how Salmonella can spread in a facility. Understand that the spread of Salmonella may be prevented by following GMPs. Discuss how you can help prevent the spread of Salmonella. Controlling Salmonella and Campylobacter in Poultry Processing Estimated Course Time - 17 minutes Salmonella and Campylobacter jejuni are two types of bacteria commonly present in the digestive tract of many animals, and the food that animals provide. This course explains how bacteria can enter and spread around a facility, and describes how to help prevent contamination through proper sanitation and good manufacturing practices. Understand what Salmonella and Campylobacter are and why they must be controlled. Explain how Salmonella and Campylobacter can enter and spread in a facility. Describe some of the actions a company can take to control these two types of bacteria. Explain how employees can help prevent the spread of these two types of bacteria. 25
Dangerous Microorganisms in Food Manufacturing (Fahrenheit) Estimated Course Time - 24 minutes A microorganism is a living thing that is too small to see with your eyes. Unfortunately, there are some dangerous ones that can grow on food or inside our bodies. This course identifies some common types of microorganisms and where they can be found. It also identifies the factors that affect the growth of bacteria, and covers some good work practices that can help prevent them from growing. Understand the risk of dangerous microorganisms and where they can be found. Identify common places in which bacteria can grow and a technique for reducing them. Recognize that bacteria grow well when a food supply, low acidity, and sufficient time are available. Understand that bacteria grow well when exposed to the proper temperature, oxygen, and moisture. Identify good work practices that can help prevent the growth of bacteria. Preventing Foodborne Illness Estimated Course Time - 16 minutes Microorganisms can cause serious foodborne illness if a dangerous type gets into food. This course explores some of the ways in which foodborne illness can spread, and examines examples of the pathogens that cause the most problems. It also introduces some of the means by which food safety is supported in a facility. Understand what causes foodborne illness and how it can spread. Identify some of the most common pathogens that can cause foodborne illness. Discuss how you can help prevent foodborne illness in a facility. Understanding Listeria and its Dangers to Food Estimated Course Time - 21 minutes Listeria is a family that includes six types of bacteria that are found everywhere in nature. One type in particular, Listeria Monocytogenes, can cause serious problems if it gets into food. This course explains the dangers of Listeria contaminating a ready-to-eat food, and how to help prevent it from forming a bio-film or collecting in a growth niche. Identify some basic properties of Listeria. Understand why Listeria poses a serious danger to public health. Understand that Listeria can spread and form biofilms, or collect in growth niches. Understand that good hygiene can help prevent the spread of Listeria. Describe how to help prevent Listeria through careful observation of a facility. 26
Bacteria Basics Estimated Course Time - 14 minutes Although some bacteria are harmless, there are many that can cause food to spoil, or make a person sick if they get into the digestive system. For this reason, we need to work hard to help keep dangerous microorganisms out of food. This course provides general information on bacteria and how they grow, and covers some basic practices for helping to limit growth. Discuss basic characteristics of bacteria. Recognize conditions in which bacteria may grow. Identify the range of the temperature danger zone. Identify work practices that can help prevent the growth of bacteria. Good Manufacturing Practices GMPs: Effective Hand Washing Techniques Estimated Course Time - 17 minutes Frequent hand washing is perhaps the best way to help prevent the spread of dirt and dangerous microorganisms. This course identifies the times when you should wash your hands, and provides a demonstration of how to properly wash your hands so all of the microorganisms are removed. Understand that frequent and effective hand washing helps prevent the spread of dangerous microorganisms. Identify when hands should be washed. Demonstrate an effective hand washing process. GMPs: Effective Hand Washing Techniques - Refresher Estimated Course Time - 7 minutes Frequent hand washing is perhaps the best way to help prevent the spread of dirt and dangerous microorganisms. This course identifies the times when you should wash your hands, and provides a demonstration of how to properly wash your hands so all of the microorganisms are removed. Understand that frequent and effective hand washing helps prevent the spread of dangerous microorganisms. Identify when hands should be washed. Demonstrate an effective hand washing process. 27
GMPs: Promoting Personal Hygiene Estimated Course Time - 16 minutes Germs and bacteria are everywhere in the world, including on you, your clothes, and the things you touch every day. This course discusses how to maintain your personal hygiene both before and during work, and explains how to properly put on sanitary gloves before working with food. It also identifies the times when gloves should be changed. Discuss good personal hygiene practices to follow both before and during work. Discuss a technique for maintaining a clean uniform at work to help prevent contaminants from spreading. Discuss the actions to take before putting on sanitary gloves. Identify when sanitary gloves should be changed. GMPs: Promoting Personal Hygiene - Refresher Estimated Course Time - 8 minutes Germs and bacteria are everywhere in the world, including on you, your clothes, and the things you touch every day. This course discusses how to maintain your personal hygiene both before and during work, and explains how to properly put on sanitary gloves before working with food. It also identifies the times when gloves should be changed. Discuss good personal hygiene practices to follow both before and during work. Discuss a technique for maintaining a clean uniform at work to help prevent contaminants from spreading. Discuss the actions to take before putting on sanitary gloves. Identify when sanitary gloves should be changed. Preventing Food Contamination Estimated Course Time - 22 minutes Food contamination can come from ingredients, packaging, processing equipment, or even people. As a food worker, you have an obligation to keep food safe from contamination. This course provides examples of three main types of food contamination, and explains how food workers can help protect food by preventing contamination from even happening. Identify the three main types of food safety hazards and give examples of each. Describe how biological cross contamination of food can occur due to the production process. Identify examples of Good Manufacturing Practices that can help prevent biological contamination. Recognize how to reduce the risk of chemical contamination due to pesticides, cleaners, allergens, and other chemicals. Describe a good work practice for preventing physical contamination of products. 28
Preventing Food Contamination - Poultry Estimated Course Time - 20 minutes Food contamination can come from ingredients, packaging, processing equipment, or even people. As a food worker, you have an obligation to keep food safe from contamination. This course provides examples of three main types of food contamination, and explains how food workers can help protect food by preventing contamination from even happening. Identify the three main types of food safety hazards and give examples of each. Understand that cross-contamination occurs when contaminants are transferred. Identify good practices to reduce biological cross-contamination. Recognize how to reduce the risk of chemical contamination due to pesticides, cleaners, allergens, and other chemicals. Describe a good work practice for preventing physical contamination of products. Preventing Food Contamination - Frozen Foods Estimated Course Time - 25 minutes Food contamination can come from ingredients, packaging, processing equipment, or even people. As a food worker, you have an obligation to keep food safe from contamination. This course provides examples of three main types of food contamination, and explains how food workers can help protect food by preventing contamination from even happening. Identify the three main types of food safety hazards and give examples of each. Understand that cross-contamination occurs when contaminants are transferred. Understand that products can be re-contaminated after processing due to cross-contamination. Identify examples of Good Manufacturing Practices that can help prevent biological contamination. Recognize how to reduce the risk of chemical contamination due to pesticides, cleaners, allergens, and other chemicals. Describe a good work practice for preventing physical contamination of products. Air Hose Safety Estimated Course Time - 4 minutes Air hoses can play an important role in the cleaning process, but they can also be dangerous if used improperly, and even be a food safety risk. This course looks at some ways to avoid injury and prevent food contamination when working with air hoses. Proper storage and maintenance practices are also discussed. Explain a step you can take to prevent personal injury when using compressed air. Describe a method to prevent air hose damage. Identify a way to prevent an air hose from contaminating food. 29
Water Hose Safety Estimated Course Time - 12 minutes This course introduces some common uses for water hoses in the cleaning process. It also discusses correct procedures to reduce the risk of food contamination, along with proper maintenance and care for hoses and nozzles. Identify a water hose food safety risk. Describe a water hose cleaning technique that can prevent contamination. Explain a way to properly care for water hoses and nozzles. Programs and Standards Basic Food Facility Defense Estimated Course Time - 19 minutes Effective food defense is essential for preventing deliberate contamination by individuals, and for ensuring the safety of your products. This course explains how to promote food defense both inside and outside a facility, and how to handle visitors and other personnel. It also introduces good practices for securing restricted areas and computer systems. Explain how to promote security outside a facility. Discuss how to handle visitors and be aware of the dangers of personnel threats by authorized employees. Explain how to promote security in restricted areas and laboratories. Understand how to maintain the security of computer systems. Describe how to recognize signs of product tampering in receiving and storage. Overview of HACCP Estimated Course Time - 16 minutes HACCP is a system that identifies potential food safety hazards, and works to reduce or eliminate those hazards before they can contaminate the food. This course identifies examples of food safety hazards, and explains how hazards can be controlled through monitoring of critical control points. It also gives examples of how an individual can personally support a HACCP plan. Explain the purpose of HACCP and its role in reducing or eliminating food safety hazards. Recognize that prerequisite programs contribute to the success of a HACCP plan. Understand that hazards may be reduced or eliminated through monitoring of critical control points. Understand that an individual can personally support a HACCP plan. 30