IOSH FOOD AND DRINK GROUP IN PARTNERSHIP …...This report summarises the results of a benchmarking...

Doc: H&S KPI’s in the Food Industry Date: May 12 Rev: 01 of 20

IOSH FOOD AND DRINK GROUP IN PARTNERSHIP WITH THE FOOD AND DRINK FEDERATION (FDF) AND DAIRY UK

SHARING HEALTH & SAFETY KEY PERFORMANCE INDICATORS WITHIN THE FOOD INDUSTRY

Supported by the FDF and Dairy UK, this health and safety benchmarking survey was distributed to all IOSH Food and Drink Group, all Dairy UK and all FDF

members. 45 companies responded to the survey employing almost 70,000 staff between them.

1.0 SUMMARY

This report summarises the results of a benchmarking survey undertaken in October 2011 by the IOSH Food and Drink Group (IOSH F&D Group), the Food and

Drink Federation (FDF) and Dairy UK. The need for accurate food industry performance data was recognised by all parties and a joint project was agreed, to add

credibility to the survey and to encourage as many participants as possible.

This is the first year that this survey has been undertaken in this format (the FDF have run similar projects in the past) and the intention is to work with the FDF

and other industry bodies representing the food sector, on an annual basis, to complete the survey. The results of the survey will be made freely available to all,

on a collective basis.


CONTENTS .............................................................................................................................................................................. PAGE

1.0 SUMMARY .............................................................................................................................................................................. 1

2.0 BACKGROUND ......................................................................................................................................................................... 4

3.0 METHOD ................................................................................................................................................................................. 4

4.0 RESULTS .................................................................................................................................................................................. 5

4.1 FATALITIES ................................................................................................................................................................................................................ 5

4.2 MAJOR INJURIES ....................................................................................................................................................................................................... 5

4.3 OVER 3 DAY INJURIES ................................................................................................................................................................................................ 7

4.4 LOST TIME ACCIDENTS (including major and over three day injuries) .......................................................................................................................... 8

4.5 FIRE & ILL HEALTH DATA ........................................................................................................................................................................................... 9

4.6 ANALYSIS OF KEY MEASURES PER INDUSTRY CATEGORY .......................................................................................................................................... 10

5.0 DISCUSSION………………………………………………………………………………………………………………………………………………………………………….11

Appendix 1: Questionnaire instructions ...................................................................................................................................... 12

Appendix 2: Key to acronyms ...................................................................................................................................................... 18

Appendix 3: Accident incident rate per year in the Food & Drink industry ................................................................................... 19

Appendix 4: Bibliography……………………………………………………………………………………………………………………………………………………………20


TABLE OF FIGURES PAGE

Figure 1: Major injuries as classified by RIDDOR by cause ................................................................................................................................................ 6

Figure 2: Over three day reportable injuries by cause ...................................................................................................................................................... 7

Figure 3: Lost time accidents by cause ............................................................................................................................................................................. 8

Figure 4: Fire & ill health data ......................................................................................................................................................................................... 9

Table 1: Incident frequency rates per category………………………………………………………………………………………………………………………………………………………………… 8


2.0 BACKGROUND

Anecdotal evidence suggests that performance information in all industries is typically difficult to obtain, can be inaccurate and may not measure performance

on a consistent basis. For this reason the IOSH F&D Group and the FDF decided to run a joint survey of its members to elicit accurate information which could be

shared. In future, surveys will be repeated on an annual basis so that trends can be identified and the project may develop to benchmark performance in other

areas. Key management information which will be calculated from the information submitted in the survey includes major injuries per 100,000 hours worked,

over three day injuries per 100,000 hours worked and over three day injuries per 100,000 hours worked in specific food industry sectors. Further information is

given in Appendix 1.

3.0 METHOD

A questionnaire was developed and agreed with the committee members of each group and the survey was sent out electronically using a SNAP tool. Members

were encouraged to complete the on line assessment and instructions were provided on how to complete the questions consistently and accurately (see

appendix 1). The survey was then analysed and the graphical and tabular information given in the results section of this report was produced. All information

was treated confidentially and the SNAP survey was anonymous. All results were used to calculate the overall figures. However frequency rates for food

industry sectors e.g. dairy, bread & cakes etc., were only calculated and published on a collective basis where the sample size was three or more companies. This

was in order to protect anonymity and to ensure that the results were representative. All figures cover a 12 month period roughly relating to 2010-11. The

precise period cannot be specified as each company recorded incidents on a different basis e.g. calendar year, financial year etc. and sites were asked to submit

data as per their current collection regime. The survey was completed in October 11 and therefore figures relate to 2010-11 dependent upon the individual

company’s reporting period.

Government SIC 92 categories were generally used to classify the type of industry although there were additional sectors included for some areas including

Frozen Food, Distribution, Snacks & Nuts and Ready Meals.

An outline of the instructions given to participants in the survey is included as Appendix 1.


4.0 RESULTS

The results were checked and analysed. Where data on the survey was not properly completed the result was excluded. In total 45 companies completed the

survey representing around 70,000 employees or approximately 14% of the food manufacturing workforce in the UK in 2007 1. Respondents were asked to

report on the no. of fires, cases of work related upper limb disorder (WRULD) and cases of occupational asthma. On occasions respondents did not complete

their sections and the data was therefore excluded from the survey.

4.1 FATALITIES

Out of the 45 respondents 2 companies reported fatalities. These were due to a fall from height and a slip, trip or fall on the same level.

4.2 MAJOR INJURIES

Respondents were asked how many major injuries they experienced in the various RIDDOR categories. There were 137 major injuries reported across the food industry sample

in total. 64 of these resulted from slips, trips and falls on the same level making it the most prevalent cause of major injuries accounting for 47% of the total. Other significant

causes of major injuries included 27 (20%) injured whilst handling, lifting or carrying, 12 (9%) falls from height and 6 (4%) hit by an object.


Figure 1: Major injuries as classified by RIDDOR in 2010/11 covering 70,000 employees

Major injuries by cause

64

27

12 11

64 3 2 1 1 1

0

10

20

30

40

50

60

70

Slip, trip or fall on the sam

e level

Injured whilst handling/lifting or carrying

Fall from a height

Hit by m

oving/flying/falling object

Contact w

ith moving m

achinery, etc.

Hit by a m

oving vehicle

Hit som

ething fixed or stationary

Another kind of accident

Contact w

ith electricity or electrical discharge

Trapped by something collapsing

Physically assaulted by a person

Exposed to/in contact w

ith a harmful substance

No. of m

ajo

r in

juries

5


4.3 OVER 3 DAY INJURIES

Respondents were asked to detail how many reportable over 3-days injuries they had had in the various RIDDOR categories as listed above.

808 were reported in total. Slips, trips & falls on the same level (313 or 39%) and injured whilst handling, lifting or carrying (224 or 28%) were

the most prevalent cause of over 3 day injuries accounting for two thirds of the total.

Figure 2: Over three day injuries as classified by RIDDOR in 2010/11 covering 70,000 employees

Over 3 day injuries by cause

011123101226

49495166

313

224

0

50

100

150

200

250

300

350


e level


Hit by m


Hit som



Fall from a height

Contact w

ith moving m

achinery, etc.

Hit by a m

oving vehicle



Exposed to fire


Injured by an animal

Contact w



Exposed to an explosion

No. of over

3 d

ay in

juries


4.4 LOST TIME ACCIDENTS (including major and over three day injuries)

Respondents were asked to detail how many lost time accidents they had had in the various categories. In total 1730 lost time accidents were

reported. Again slips, trips & falls on the same level (597 or 35%) and injured whilst handling, lifting & carrying (460 or 27%) were the most

prevalent cause of lost tome accidents accounting for 62% of the total.

Figure 3: All lost time accidents as classified by RIDDOR in 2010/11 covering 70,000 employees

All lost time accidents by cause

597

460

170 155

100 107

46 4621 12 4 5 4 2 1

0

100

200

300

400

500

600

700


e level


Hit by m



Fall from height

Hit som


Contact w

ith moving m

achinery, etc.

Hit by a m

oving vehicle



Exposed to fire

Contact w




Exposed to an explosion

Injured by an animal

No. of lo

st tim

e a

ccid

ents

(all)


4.5 FIRE & ILL HEALTH DATA

Respondents were asked to report on some other miscellaneous data (see below). It is generally acknowledged that this type of data is

typically either not reported accurately or seriously under reported so no conclusions can be drawn from these results. This data has been

collected as a baseline for future years and in order to encourage companies to collect this data so that more accurate reporting can be

achieved. This data related to incidents such as fires, back injuries, occupational asthma and hearing loss etc.

Figure 4: Incidents of fires and ill health reported in 2010/11 covering 70,000 employees

27

32

24

32 31 31 31

0

5

10

15

20

25

30

35

Number of fires

Reported back injuries

Reported mental ill

health

Number of WRULD

Incidents of occupational

asthma

Incidents of occupational

dermatitis

Incidents of occupational hearing loss


4.6 ANALYSIS OF KEY MEASURES PER INDUSTRY CATEGORY

Table 1: Incident frequency rates per category

Various incident frequency rates were calculated from the data submitted. The overall over three day accident frequency rate (AFR) of the food industry

was 0.62 which means that 62% of workers in the food industry will suffer an over 3 day accident during their working lifetime. Various accident frequency

rates were calculated for the various industry categories so that this data can be used for comparative purposes. Due to the very low number of fires,

WRULD and occupational asthma reported no incidence rate has been calculated. All figures are the number of incidents per 100,000 hours.

Category1. Food

industry

Dairy Fish Bread &

Cakes

Fruit & Veg Biscuits Frozen Miscellaneous

Food

Manufacture

No. employees 2. 68,650 18,105 837 4,016 1,500 5,571 1,174 12,149

Major injury AFR 0.11 0.11 0.46 0.15 0.00 0.13 0.10 0.10

Over 3 day AFR 3. 0.62 0.64 1.26 0.59 2.11 1.83 1.04 0.71

LTA AFR (inc. major & over

3 day injuries)

1.33 1.14 2.29 1.41 4.52 4.56 2.39 1.32

Slips & trips AFR 0.29 0.34 0.69 0.28 1.78 0.50 0.21 0.33

Manual Handling AFR 0.19 0.19 0.46 0.20 0.20 0.58 0.42 0.21

Over 3 day incident rate

(per 100,000 employees)

1177 1121 1314 1245 4200 2800 1704 1383

Major incident rate (per

100,000 employees)

200 199 478 274 0 197 170 189

1. Not all categories were reported upon due to the low number of returns – hence the figures reported for the specific categories above will not add up to the grand total of 68,650 employees.

2. No. of employees reported upon to give an indication of sample size

3. As the survey was undertaken prior to the amendment to the RIDDOR Regulations in April 12, this survey includes ‘over 3 day’ accidents not just ‘over 7 day’ accidents


5.0 DISCUSSION

This is the first time that a joint IOSH F&D and FDF survey has been undertaken. The response rate achieved was 45 respondents covering

almost 70,000 employees, giving a reasonable sample size of approximately 14% of the workforce. This will be built upon in future surveys.

The over three day accident frequency rate was 0.62 per 100,000 hours worked and data for other food industry categories were also

calculated to enable industry categories to compare their performance.

The causes of major and over 3 day injuries were not unexpected and compared favourably with information previously reported by HSE.

Slips, trips and falls on the same level were the top cause of major, over 3 day and lost time accidents with injured whilst handling lifting or

carrying a close second. Falls from height accounted for a significant number of major, over three day and lost time accidents. No data was

excluded from the reported figures. Some of the industry specific data has a smaller sample size (see Table 1) and this data may not be as

accurate as the overall figures for the food industry.

The reported accident incident rate for the IOSH/FDF Food & Drink Survey is slightly lower than the HSE reported figure for 2010/11 (1177

compared to 1354). This may be because the HSE figures include all company sizes whereas the larger companies (which should have better

safety performance) are more likely to have participated in this voluntary survey.

This survey will be repeated in a similar format for 2011-12 which will allow more accurate data to be collected and appropriate comparisons

to be made.

Doc: H&S KPI’s in the Food Industry Date: May 11 Rev 01 of 20

Appendix 1: Questionnaire instructions

SHARING HEALTH & SAFETY KEY PERFORMANCE

INDICATORS WITHIN THE FOOD INDUSTRY

SUPPORTED BY IOSH FOOD & DRINK GROUP/FDF/DAIRY UK

Background

Health & Safety key performance indicators for the food industry can be inaccurate and of

dubious value for benchmarking due to:

(a) acknowledged under reporting by companies nationally;

(b) defective population data used by HSE;

(c) historical nature of published figures; and

(d) the lack information relating to fire incidents, frequency rates and occupational health

incidents

Because of the above, food companies could benefit from more accurate and varied

information in a simple format.

Ground Rules

1. Food companies are invited to participate and submit a return annually.

2. The information will be treated as confidential and not circulated except as outlined below.

3. All food industry companies who are interested will have access to the collated

information. If they have not previously participated in the benchmarking exercise they

will be encouraged to participate after utilising the information.


4. A collated report will be circulated once per annum and will be published on the IOSH Food

& Drink Group and FDF websites.

5. Figures to be submitted for the HSE year of April to March or for the nearest year if used by

a company i.e. a calendar year or the company’s reporting year.

e.g. HSE year = 04/09 to 03/10

or Calendar year = 2009

or Company year (example) = 05/09 to 04/10

6. Figures to be submitted under the food sector headings detailed on the survey form.

7. Select the food industry category nearest to your product makeup. Where there is more

than one site in a group of companies submitting a return please submit a separate return

for each category. This will provide valuable information about differences in accident

rates between different industry sectors.

8. When deciding the category for an individual business, it is the ‘principal function’ of that

business which should be taken into account.

9. Lost time accidents are those where a full shift or more has been lost up to three days.

10. Numbers of personnel/ hours worked recorded in calculations will exclude short-term

external contractors (e.g. a repair company who are only called in intermittently when

needed), but should include ‘long term’ contractors/agency staff on routine duties.


11. Employee figures are the average total no. of all employees at all sites during the year

within a company e.g. Bloggs Ltd, Dairy Products = 465, made up from HQ Building -52

employees, Factory- 303, Four Depots - 110 (inc. Drivers). Part-time employees are to be

included as one person.

12. Where hours worked are not available estimate the no. of hours worked to enable a

frequency rate to be calculated. One employee will be assumed to work 40 hours per

week for these purposes. No account will be taken of part time workers or overtime

worked.

13. For the purposes of the return a fire includes any fire whether it results in loss or not.

14. Initially some simple occupational ill health data will be collected such as the number of

cases of WRULD’s and occupational asthma.

15. The following information will be calculated from the collated data submitted and

circulated as agreed above:

Major injuries per 100,000 hours (MI Frequency rate)

Major injuries per 100,000 employees (MI Incidence rate)

Over three day injuries per 100,000 hours (accident frequency rate)

Over three day injuries per 100,000 employees (Accident incidence rate)

Over three day slips & trips injuries per 100,000 hours

Over three day manual handling injuries per 100,000 hours

No. of fires

No. of fires per 100,000 hours

No of WRULD per 100,000 hours

No of occupational asthma per 100,000 hours

No. of back injuries


No. of cases of mental ill health

No. of cases of occupational dermatitis

No. of cases of occupational hearing loss

Over three day injuries per 100,000 hours per product category


FOOD INDUSTRY CATEGORIES

CATEGORY HSE RE (SICR 92)

INCLUDES

Biscuits 15.82 Preserved Pastry & Cakes

Bread and Cakes 15.81 Roll, Fresh Pastry & Cakes, Pies

Cocoa, Chocolate 15.84 Sugar, Confectionary

Crude Oils & Fats 15.41 Olive Oil, Soya Oil

Dairy Products 15.51 Milk Butter, Cheese, Yoghurt

Fish Processing 15.20

Fruit & Vegetables 15.33 Processing, Preserving, Canning, Jams, Marmalades, Jellies

Grain Milling 15.61 Flour, Meal Breakfast Cereals, Rice Vegetables

Ice Cream 15.52 Includes sorbet

Margarine 15.43 Cooking fats

Meat Processing 15.13

Pastas 15.85 Noodles

Poultry 15.12 Slaughter, Prepared Dishes

Slaughtering 15.11 (not Poultry)

Soft Drinks 15.98 Mineral Water (not Fruit Juice)

Soups 15.89

Starch 15.62 Gluten, Tapioca

Sugar 15.83 (not Glucose)

Tea & Coffee 15.86

Animal Feeds 15.71 (not Oil Seed)

Other Food Manufacture 15.89/9 e.g. Colourings, Seasonings, Spices and other ingredients (e.g. bakery ingredients)

Other ref

Frozen Foods Frozen

Distribution Distribution inc transport


Snacks, Nuts and Crisps Snacks

Ready meals Ready meals All types

Note: Where categorising several companies within a group consider the ‘principal function’ of each company.


Appendix 2: Key to acronyms

1. RIDDOR - Reporting of Injuries, Diseases and Dangerous Occurrences Regulations 1995 (as Amended)

2. WRULD – Work related upper limb disorder (also sometime referred to as RSI (repetitive strain injury)

3. HSE – Health & Safety Executive

4. Reportable – this refers to an over three day injury in the context of this report. (Please note this survey was conducted prior to the

amendment to the RIDDOR Regulations introduced on 6th April 2012)

5. Major injury – this is an injury reportable under Regulation 3 Schedule 1 of the RIDDOR Regulations

6. AFR – is an accident frequency rate which for the purposes of this report is reported per 100,000 hours

= No. of over 3 day accidents x 100,000/No of man hours worked

e.g. for a firm with 1000 employees who have worked a total of 2.4 million hours, with 7 over three day accidents the accident frequency rate

would be:

7 x 100,000/2400000 = 0.29 per 100,000 hours

7. Incident rate – is an accident rate which is calculated per 100,000 employees

= No. of over 3 day accidents x 100,000 employees/No. of employees

e.g. for a firm with 1000 employees with 7 over three day accidents the accident incident rate would be

7 x 100000/1000 = 700


Appendix 3: Accident incident rate per year in the Food & Drink industry

Graph showing a 55% reduction in injuries in food and drink manufacture since 1990 with an incident rate per 100,000 workers of 1354 in

2010/11

Source: Health & Safety Executive

1200

1600

2000

2400

2800

rep

ort

ed

in

juri

es/1

00

,00

0 w

ork

ers


Appendix 4: Bibliography

1. Research into UK Food & Drink Manufacturing – Final Report (Desk Research) David Boothby, Suzanne Clark, Stuart Attwood, Bingül Augustin (Aug 2007)

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