1
Documents change faster than training does.
Specs, SOPs, work instructions and sanitation procedures are revised continuously. The revision goes into the document system; the retraining happens as a verbal briefing at shift handover, if at all. Six months later nobody can say which version each operator was trained against.
The risk: a training record that points at a superseded document.
2
GFSI audits ask for records at the individual level.
SQF, BRCGS and FSSC 22000 all expect a documented training program with records showing that named personnel are trained for the tasks they perform. “The team was briefed” is not a record, and neither is a sign-in sheet with eight illegible signatures.
The risk: a non-conformance on a clause you had covered in practice.
3
Temps and transfers arrive mid-shift.
Agency workers, seasonal peaks and shift transfers put people onto a line quickly. GMP, allergen awareness, hygiene and job-specific instruction all need to happen before they touch product — and be recorded, even for someone who works four weeks.
The risk: an untrained operator monitoring a critical control point.
4
The workforce is not sitting at a computer.
Production staff have no desk, often no work email, and in many plants no shared first language. Training designed for an office rollout stalls partway through the crew, and someone ends up chasing the rest by hand.
The risk: completion that never reaches the whole shift.