Creating Standard Operating Procedures

Written procedures for following certain sequences in operations can prevent expensive mistakes. For instance, in a certain process industry, an operator turned on a pump, without opening the outlet valve on the other end of the transfer line, causing all the gaskets to blow on the heat exchanger. In another incident, a receiver at a plastic bottle plant, unloading a rail car of resin pellets, transferred them into the wrong silo, contaminating both resins, and tying up a silo that could no longer be used. The manufacturer also had to find someone who would take all the contaminated resin out of their silo.

Following written SOPs can ensure that injuries and accidents can be avoided. Written SOPs can also prevent hourly associates from taking short cuts in their operations; in some cases these short cuts may not be intentionally to cause difficulties, but workers may feel they have a better way to do a task, and may be unaware of unintended consequences.

It is also beneficial to periodically review SOPs to ensure they are accurate and up-to-date, reflecting any product or process changes. In one warehouse distribution center, during a discussion of cleaning procedures, the general manager asked whether he really needed a written procedure, stating to “take a broom and sweep.” Depending on the quality of his workforce, he may need a written SOP, as workers cleaning would sweep aisles and wide open spaces, but would not sweep corners, behind and beneath equipment and pallets.

It is also true that in fairly small plants with a small workforce, many actions will be handled more casually and verbally than having all work instructions documented. It is a manager’s discretion when determining how detailed to make SOPs and operational methods.

Jim Carter is a senior consultant with ASI Food Safety Consultants (St. Louis, Mo.). Reach him at 800-477-0778.