Practicing GAP · and Shitsuke=Sustain) Kaizen Meeting PDCA Is GAP difficult to achieve? Is GAP...

Practicing GAP

AEON Agri Create Co., Ltd.

What is GAP?

Copyright AEON AGRI CREATE CO., LTD. All Rights Reserved.

What is GAP?

Good Agricultural Practices (GAP)

To ensure better work efficiency and safety, workers who actually work at

the site take the initiative to work on resolving problems using a bottom-

up system

5S (Seiri=Sort,

Seiton=Set,

Seiso=Shine,

Seiketsu=Standardize,

and Shitsuke=Sustain)

Kaizen

Meeting PDCA

Is GAP difficult to

achieve? Is GAP expensive?

Actually, it is not different than

what you do every day. No, GAP does not require much money.

＝ Good Agricultural Practices, Production process management system

for farming

＝ Improvement activities at farming sites


Three safety issues addressed by GAP

Food safety

Work safety Environment

conservation

Farming-related

accidents

Bovine spongiform

encephalopathy (BSE) Bird flu

Fraudulent

claiming of origin

O-157 (E. coli strain) Food terrorism

Residual agricultural chemicals

Exposure to

radioactive

substances

Aging

Heatstroke

Lightning

Torrnados

Endangered

species

Drought

Biodiversity

Water

contamination

Biological

concentration

Handling poisonous

materials

Unauthorized

materials

Preservatives and

additives

Drift

Using larger

machines

Localized heavy

rainfall

“Safety” means “less risk”

What is risk assessment?


Risks Anything that we don’t want to happen

Always present in any kinds of situation

Hazards and risks

Hazards Risk factors and anything related to risk

Hazards themselves are not risks.

(Examples: People, bacillus, viruses, chemicals, work, instruments, and weather)

It is impossible to eliminate risks. Therefore, when minimizing risks,

all we can do is either help prevent risks or minimize the damage caused

by risks

Extent of risk can be reduced

Risk

Probability

Severity

GAP are essentially kaizen activities to reduce “P” and “S”


HACCP concepts

HACCP: Hazard Analysis and Critical Control Points

HACCP is a science.

It is changing symptomatic measures to preventative measures

It is centralization instead of decentralization

Grinding Kneading Heating Cooling Packaging

Escherichia coli O157 dies out when heated for at least one minute at 75 °C -->

heating process should be well controlled.

Example: Producing hamburger

patties Expected risk: food poisoning due to Escherichia coli

O157 derived from beef

This is the

Critical

Control

Point


Example practice: Identifying hazards and risks

What hazards and risks are expected when loading cargo on a forklift? (Note: The photo below is given as an example only.)


Identifying hazards and risks

Forklift

Hazards Risks Operator

Damage to forklift

Contamination with foreign matter

Operator injury or death

Cargo

Rain

Surface unevenness

・・・

Forklift may slip

Cargo shifting

・・・

Harzards and risks may not always correspond one-to-one.

If multiple hazards are combined, then they are considered risks.


Formulating measures starting with larger risks

Risks P S R

Operator injury or death

Damage to forklift

Contamination with foreign matter

Forklift may slip

Cargo shifting

We define the numbers below as follows (you can define them in your own way) Probability “P” 3＝Frequent ２＝Occasional 1＝Unlikely

Severity “S” 3＝Life-threatening, financial crisis ２＝Injury or damage 1＝Problematic


Formulating measures starting with larger risks

Risks P S R

Operator injury or death 2 3 6

Damage to forklift 1 2 2

Contamination with foreign matter 1 1 1

Forklift may slip 2 1 2

Cargo shifting 2 2 4

--> Formulate measures starting with larger risks

We define the numbers below as follows (you can define them in your own way) Probability “P” 3＝Frequent ２＝Occasional 1＝Unlikely

Severity “S” 3＝Life-threatening, financial crisis ２＝Injury or damage 1＝Problematic


Make the measures specific: Assign a person in charge and

specify a time period

Formulate countermeasures using the 5W1H (who, what, when, where,

why and how) philosophy and always leave a record.

Carry out the countermeasures and verify their appropriateness.

Periodically review the risk assessment.

For example, focus on operator hazards and look at measures

to reduce the risk of operator injury or death

Avoid being rushed

Do not hang anything from neck

Wear thick gloves

Participate in a life-saving training

program

Improve operation skills

Participate in safety education

Wear a hard hat

Wear safety shoes

Preventative measures Measures to minimize damage

・・・

・・・

Company management and GAP


Commitment to safety

Developing Japan’s agricultural producers from farmers into farm managers

requires a company-wide commitment to Safety First.

Food-related accidents are very likely to continue, and their effects

last a long time.

Once a food-related accident occurs, the business may immediately

fail.

Food safety is the producer’s obligation, and GAP initiatives are

what protect you (or your company).

I know it is better than

nothing, but GAP is

costly.

I’m too busy harvesting to be

involved in GAP.

GAP is useless. My vegetables

are selling anyway.


History of our company and Global GAP (GGAP)

2009 2010

Establishment

2011 2012 2013 2014

1

2015

Since our establishment, we have been focusing on acquiring GGAP

certification as a way to implement overall system design.

This started an initiative to obtain certification in 2010.

In 2011, multiple farms began participating in the GGAP initiative.

They obtained certificates through collaboration between headquarters

functions and multiple farms.

In FY2015, farms under direct management will be able to obtain certificates.

5

8

12

15

18 (planned)

Number of farms under direct management

that obtained the GGAP certificate


Checklists as a tool for introducing GAP

(Example: GGAP Ver. 4 standard document “Examples Control Point and Conformity

Criteria (CPCC)”)

Std.

No.

Control Points ＝ Points to be observed

Level Conformity Criteria ＝ What are the criteria for conformity?

AF.

3.2.2

Do you have sanitary

instruction documents

targeting all workers?

Lower

level

Instructions regarding sanitation, for example, must be in the form

of clear signage (pictures) in the language most commonly used by

operators and posted in a highly visible location. The sign must

contain the following information: －Hands must be washed

－Cuts must be covered

－Smoking, eating, and drinking are allowed in designated areas

only －Notifications of infections or health conditions. These must

include notifications about signs of illness (e.g. vomiting, jaundice,

or diarrhea) and may not directly contact products or surfaces. －Wear appropriate protective gear. No exceptions.

New farmers do not know what might be dangerous at the farm site or what

should be managed, and do not have the skills to accurately identify these

problems.

I get it!

We have to pay

attention to these

items!


Recognizing effective risk assessment

Work instructions are ignored at the site!

Regulations end up being only on

paper

How can we make rules executable at the site?

How can we make workers see the necessity of the regulations?

Resolve problems that workers actually suffer from first.

Throughly prevent recurrence of accidents that have actually taken place.

・Prioritize problems according to the results of the risk assessment.

・Prevent problems instead of responding to symptoms (essential spirit of

HACCP)

Recognize

effectiveness


Link GAP with routine work

Example: Spraying pesticides

Enter a pesticide spraying schedule in the

system.

The following items can be

executed on a cloud system:

• Checking registered agricultural

chemicals (to ensure there are

no violations)

• Collecting cultivation records

• Stock management

• Checking the number of days

before harvest

• Cost analysis

• Creating visual reports

Input screen covering record

items required by GGAP

The headquarters and farms can

output the record whenever

necessary in whatever form they

need

(Conforms to GGAP) Spray pesticides according to the

instructions output from the system

Instructions

Fixing

work

records

Case study on food safety


Education to prevent the misuse of agricultural

chemicals

Never let them touch

pesticides

Introducing an in-house qualification system for handling agricultural

chemicals

Unqualified person Pesticide sprayer Spray instructor

Sprays pesticides as

instructed

Selects a pesticide and instructs on

spraying practices

Keeps the key to the storage

cabinet.

Requirements:

• Participated in Off-JT for agricultural

chemicals

• Participated in Off-JT for agricultural

chemical preparation

• Participated in OJT for dispensers

• Recommended by supervisor(s)

• Approved by AEON Agri Create.

Requirements:

• Officially capable of handling agricultural chemicals or

has participated in in-house special seminars and

passed comprehension tests.

• Has prepared a plan to control insects without the

help of others and is recognized by AEON Agri

Create.

• Recommended by supervisor(s)


Safe storage of agricultural chemicals

Keep preventative

instruments and

equipment near the

preparation area.

• Store agricultural chemicals in a locked cabinet.

• Label them as poisonous materials

• Keep powder or granular agents on the upper

shelf, with liquid agents on the lower shelf.

• Store in a cabinet made of fire-resistant and

waterproof materials.

• Calibrate measuring devices every year.

• Make an inventory of agricultural chemicals at

least once every three months.

Liquid chemicals may overturn and

spill, so they must be stored in a tray.


• Carry out on seed rice to be used.

• Carry out on unpolished rice after

hulling.

• Carry out tests based on the Water Supply Act for all water sources.

• Conduct a separate test if there is any possibility of contamination.

• Carry out this test before opening or expanding a field to address the risk of

environmental contamination and in cultivation.

• Use in the fertilizing plan, and carry out this test before planting to ensure plant

nourishment.

• Measure the amount of microbes to judge soil fertility

• Have each farm carry out itemized tests once a

year.

• Increase test frequency at so-called “hot

spots”. • Voluntarily carry out tests on manure and other

materials to be used in the fields.

• Have each farm carry out itemized tests before shipping.

• Obtain specimens from high-risk areas.

• Use appropriate test items for the agricultural chemicals used.

• Make sure there are no problems with the cultivation history.

• If any unused agricultural chemicals are detected, find out why.

Test systems

Test for residual

agricultural chemicals

Test for exposure to

radioactive substances

Water analysis

Soil inspection

DNA test


5S (Seiri=Sort, Seiton=Set, Seiso=Shine,

Seiketsu=Standardize, and Shitsuke=Sustain)

Sorting and setting are the foundation of risk control!

There are many thinsg you can do without spending

much money.

Ideas for

managing

blades


Sanitary control (handwashing)

Get creative if there is

no water supply.

Handwashing

instructions

Paper towels

Trash can for paper towels

(Paper towels can be disposed of

without touching the lid)

Detergent for

food Alcohol for

sterilization

Fragrance-

free soap

Basic

hand

washer

Tempora

ry

lavatory

Case study on work safety


Preparing hazard maps


Preparing for potential incidents and accidents

Operating machinery Weeding Prepare a first-aid kit

(in offices and vehicles)

Establish an

emergency

contact network

How to call the ambulance or

fire department

Fasten chin strap

on hard hat

Tighten

sleeves

Wear gloves

Wear face

guard or goggles

Wear shoes properly.

Shoes without

shoelaces are ideal

Do not hang pens or

cell phones from neck

Put pants in boots

Wear shin guards

Work clothes

with long sleeves

and high boots

Vibration-proof gloves

High boots

Wear a hard hat


Safe operation training for agricultural

machinery

Provide safe operation training with the help of the Ministry of Agriculture, Forestry and

Fisheries and agricultural machinery manufacturers


Kaizen meetings

Hold frank and candid discussions once in a month with the participation of

all employees, part-time workers, and temporary workers.

I almost got heat

stroke, it’s so hot!

You did?

Prepare a potable

shade area. Make it a rule

to always wear

a hat.

Start working a bit

earlier than usual.

Take breaks more often

A positive cycle can be generated in

improvement activities by taking

action on all requests.

Case study on environmental

conservation


IPM

IPM: Integrated Pest Management A general term for “the skills to use agricultural chemicals in a smart way”

An initiative that combines biological, physical, chemical, and tilling/sowing techniques while

maximizing the effectiveness of agricultural chemicals, rather than completely avoiding the

use of agricultural chemicals.

• Remove weeds that may

become a hotbed for

harmful insects

• Use insect-proof netting

• Select disease-resistant

varieties

• Disinfect instruments

• Use mulch

• Patrol fields

• Pheromone traps

• Collect regional forecasting

information

• Identify natural enemies

• Spray agricultural chemicals on fields

in rotation

• Use natural enemy insects

• Use Bacillus thuringiensis (BT)

insecticide

• Use insect traps

• Weed without chemical herbicides

Preventative measures Observation measures Measures to prevent

harmful insects

Future challenges


Challenges in promoting GAP certification

• Improving recognition among buyers and consumers

• Developing to the point that managers can be separate from

operators

• Enhance farming consultations and advisory system • Prepare country guidelines early, adding Japan’s specific

interpretation.

• Increase unit prices and quantities to cover increased

production costs.

Food safety is a non-

competitive area Create initiatives that transcend the

boundaries of companies and industries!

We will do our best to help you. We provide GAP manuasl and other documents free of

charge.

We provide on-site seminars for people both in and out

of AEON Agri Creates.

Practicing GAP · and Shitsuke=Sustain) Kaizen Meeting PDCA Is GAP difficult to achieve? Is GAP...

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