Specified Skilled Worker(i)Manufacture of Food and Beverages
Skills Proficiency Test

Textbook for
Learning
4th Edition

February 2024

The Organization for Technical Skill Assessment of Foreign
Workers in Food Industry

Introduction
This Manufacture of Food and Beverages Skills Proficiency Test Textbook for Learning
is designed to help those who want to work in the manufacture of food and beverages(food factories, etc.) as a Specified Skilled Worker (i) learn basic knowledge and skills.
We have rearranged the structure of the textbook to make it more practical andsystematic.
Based on the basic concept of food and beverage manufacturing, this textbook
introduces not only the knowledge and skills required for the job, but also the basic
terminology. Depending on where you work, methods, terminology, and the like may
differ from this textbook. In such case, follow your workplace’s approach. The basic
idea is the same even if the methods and terminology are different.
Use this textbook to learn the food hygiene and labor safety knowledge and skills
required for the Specified Skilled Worker (i).

©OTAFF

Contents
Introduction
CHAPTER 1: SKILLS REQUIRED IN THE MANUFACTURE OF FOOD AND
BEVERAGES ··························································································· 11.

Various manufacturing processes of food and beverages ···························· 22.

Skills required for Specified Skilled Workers (i) in the Manufacture of Food andBeverages························································································· 3(1)Food hygiene ················································································· 3(2)Labor safety ··················································································· 3

CHAPTER 2: FOOD HYGIENE····································································· 4
1.

Food hygiene ····················································································· 52.

Hazard ····························································································· 7

3.

4.

(1)

Physical hazard ·············································································· 7(2)Chemical hazard ············································································· 8(3)Biological hazard············································································ 10

General hygiene control ······································································ 15(1)5S ······························································································· 15(2)

Hygiene control of facilities, equipment, and utensils······························ 16(3)

Hygiene control by workers ······························································ 18(4)

Hygiene control of ingredients and food ·············································· 27

Hygiene control by HACCP ·································································· 37(1)

Seven principles of HACCP ······························································ 37(2)

Critical control point and management standard···································· 38(3)

Deviation from management standard ················································ 39(4)Remedial action ············································································· 39(5)Recording ····················································································· 40©OTAFFCHAPTER 3: LABOR SAFETY ···································································· 41
1.

2.

3.

4.

5.

Industrial accidents in the manufacture of food and beverages ···················· 42(1)Relationship between experience and industrial accidents ······················ 42(2)Major industrial accidents ································································· 43

Important things to be followed for no industrial accident ···························· 44(1)5S ······························································································· 44(2)

Proper attire ·················································································· 45(3)Follow operating procedures and rules················································ 47(4)

Use machines correctly ··································································· 48(5)Use detergents and chemicals with caution·········································· 51

Response to abnormal situations or industrial accidents ····························· 51(1)

When an abnormal situation occurs ··················································· 51(2)

When an industrial accident occurs ···················································· 51

Build awareness of danger ·································································· 53(1)Learn about cases of industrial accidents ············································ 53(2)Participate in near-miss activities ······················································· 53(3)Participate in risk prediction training ··················································· 54

Cases of near misses and prevention of industrial accidents ······················· 55(1)“Falls” accident ·············································································· 55(2)“Caught in or in between” accident ····················································· 57(3)“Cuts/Scratches” accident ································································ 58(4)“Falling” accident············································································ 58(5)“Burn” accident ·············································································· 59(6)“Lower back pain” accident ······························································· 59(7)“Heatstroke” accident ······································································ 60(8)“Crash” accident ············································································ 61©OTAFF

SUPPLEMENTARY MATERIALS ································································· 62
Examples of safety signs used in the workplace ...................................................... 62
INDEX ·································································································· 65
Notes ........................................................................................................................ 73[References] ............................................................................................................. 74©OTAFF

Chapter 1: Skills Required in the Manufacture of Food and Beverages-1©OTAFF

1.

Various manufacturing processes of food and beverages

Food and beverages are essential to our lives. The manufacture of food and beverages
involves the production of food and beverages at factories.
There are various manufacturing processes of food and beverages: food processing
such as ham and sausage, canned fish, seasoning, bread and sweets, lunchbox,
prepared foods and frozen foods, and beverage manufacturing such as juice, tea, andcoffee.
According to the Ministry of Agriculture, Forestry and Fisheries statistics, the domestic
production of the food processing industry in Japan has been about 37 trillion yen forthe past few years.

Domestic production(Unit: 1 billion yen)

Movements in domestic production in the food processing industry(Year)

Domestic production in the foodprocessing industry

Ready-made meals,sushi, box lunches
2.8 (8%)(2021 estimate)

Retort food0.2 (0%)

Seasoning
1.8 (5%)Precooked frozen
packed food
0.6 (2%)

Beverages
3.8 (10%)Meat
2.6 (7%)

Food processing
industry
36.5
Others9.6 (26%)

Confectionery
3.3 (9%)[Classification, production value (trillion yen), and percentage]

Livestock products
3.5 (10%)

Seafood products
2.9 (8%)

Refined grain
and milling
2.4 (7%)

Bakery1.9 (5%)
Noodles
1.0 (3%)

Source: The Ministry of Agriculture, Forestry and Fisheries website, “2021 Agriculturaland Food-related Industry Economic Accounts (Estimates)”-2©OTAFF

2.

Skills required for Specified Skilled Workers (i) in the Manufacture of Food andBeverages

Specified Skilled Workers (i) in the Manufacture of Food and Beverages work in theindustries involving livestock products, seafood products, seasoning, bakery andconfectionery products, ready-made meals, precooked frozen packed foods, and softdrinks and carbonated water. All industries require knowledge and skills in foodhygiene and labor safety.
(1)

Food hygiene

Hygiene is about protecting life. “Food hygiene” means that people do not get sick or
injured by eating food.
“Hygiene control” in food production is to produce (control) food so that people who eat
it do not get sick or injured.
If people eat food with inadequate food hygiene control (unsafe food), they will get sickor injured. The company that made the food will lose credibility.
(2)

Labor safety

Industrial accidents such as injuries have occurred in food manufacturing plants.
To avoid injury in factories and workplaces, you must properly wear safety protective
equipment such as work clothes and helmets.
And you must follow the rules and operating procedures set by the factory. This also
applies to the use of machines and utensils.
Protecting the safety and health of workers is “labor safety.”

Operating procedures
Manual-3©OTAFF

Chapter 2: Food Hygiene-4©OTAFF

1.

Food hygiene“Food hygiene” means that people do not get sick or injured by eating food.
The basis of food hygiene is the following actions:• Wash your hands.
• Wear work clothes and gloves correctly.
• Use clean equipment, machines, and utensils.
• Store food and ingredients at a fixed temperature, etc.
Basic hygiene control is common in all workplaces when making any food. This iscalled “general hygiene control.”For general hygiene control, the following things are important:(1) 5S(2) Hygiene control of facilities, equipment, and utensils(3) Hygiene control by workers(4) Hygiene control of ingredients and food
After carrying out general hygiene control, depending on the type of food to be
produced and the characteristics of the workplace, equipment, and machines,
particularly critical processes (“critical control points [CCPs]”) may be determined tocarry out hygiene control.
Hygiene control that combines general hygiene control with management of the criticalcontrol points (“HACCP Plan”) is called “hygiene control by HACCP.”
HACCP refers to the Hazard Analysis and Critical Control Point. This term is also usedin Japanese.

-5©OTAFF

Management ofcritical control point(HACCP Plan)

General hygiene
control

Figure: Hygiene control by HACCP“Hazard” is a cause of illness or injury. “Hygiene control of food production,” whichmeans making food so that people who eat it do not get sick or injured, can also mean
making food so that it does not contain hazards. Both general hygiene control and thehygiene control by HACCP are activities to ensure that food does not contain hazards.
Next, we will learn about hazards, general hygiene control, and the hygiene control by
HACCP.

-6©OTAFF

2.

HazardHazards include physical hazards, chemical hazards, and biological hazards. The
hazards to be careful of in food production are explained below.
(1)

Physical hazard

Among the hazards, factors that are likely to cause injury to people due to physicalfactors are called “physical hazards.” These result in chipped teeth due to foodhardness or cuts in the mouth due to food sharpness.
The following table shows typical examples of physical hazards.
Pieces of metal,
glass, plastic, etc.
Stone

They may be in ingredients or come from machines during
food production.
It may be in the ingredients.

“Foreign object” is a substance that was contained in an ingredient and was notremoved before production, or a substance that was not contained in an ingredient or
food but entered the food during production by mistake. For example, eggshells thatshould have been removed but ended up in dishes such as tamagoyaki (Japaneserolled omelet) are foreign objects. Among foreign objects, those that are hard like metal
pieces, glass pieces, and stones are called “hard foreign objects.”

Metal

Glass

Plastic

Stone

To prevent physical hazards from entering the food, it is necessary to prevent
contamination with hard foreign objects. For this reason, wash, sort, and prepare
vegetables that may have soil or pebbles on them to remove them. Cut off the roots ofvegetables and remove shells of shellfish, as well as gills and bones of fish. Whenstoring ingredients that have been prepared in this way or foods that have been cooked,
cover them with a lid.

-7©OTAFF

Foreign objects that are not hard (e.g. insects, hair, and pieces of paper) are not aphysical hazard because they do not cause wounds in the mouth or throat. However,the presence of such foreign objects can lead to complaints or returns, as the food is
considered unclean and unsanitary. Such non-hard foreign objects should also be kept
out of the food.
When you find a hard or non-hard foreign object in the food, stop the work immediately
and report it to the person in charge. Foreign objects are not only a hazard. They also
discredit the company.
(2)

Chemical hazard

Among the hazards, chemical substances such as allergic substances, histamine,solanine in potato sprouts, sanitizing agents, and other chemicals are called “chemicalhazards.”
1) Allergic substance“Allergic substances” are substances that cause allergic reactions and are also called
allergens. “Allergic reaction” is when the body overreacts to a substance that hasentered the body and causes certain symptoms. The symptoms include itching, hives,
swelling of the lips or eyelids, a runny nose or sneezing, difficulty breathing, andnausea. Severe symptoms can cause death.
In Japan, by law, processed foods made from allergic substances that cause a highnumber of symptoms or cause severe symptoms must be labeled as containing thoseingredients. Among them, “specified ingredients” are those that are required to belabeled, and “items equivalent to specified ingredients” are those that arerecommended for labeling.
.

-8©OTAFF

8 specified ingredients (labeling required)

ShrimpCrab

WalnutWheat

Buckwheat

Egg

Milk

PeanutNote: As of March 9, 2023, walnuts were transferred from items equivalent to specified ingredients to specified ingredients.

20 items equivalent to specified ingredients (labeling recommended)

AlmondAbaloneSquid

Salmon roe

OrangeCashew nut

Kiwi fruit

Beef

SesameSalmonMackerel

Soybean

Chicken

BananaPork

Matsutakemushroom

Peach

Wild yamApple

GelatinMachines and utensils used to cook ingredients containing allergic substances should
not be used to cook another ingredient. This is to prevent allergic substances fromentering food made with ingredients which do not contain allergic substances.
Machines and utensils used to cook ingredients containing allergic substances must
be washed.
It is also important to separate cooking utensils such as cutting boards and knives byingredients. For example, use different cutting boards and knives for cutting boiled
eggs and for cutting other ingredients. This is to prevent allergic substances of eggs
from getting on other ingredients.
Cleaning and sanitizing agents are also chemical hazards. When cleaning or sanitizing
agent is used for ingredients or cooking utensils, the agent should be washed off withwater so that it does not remain on food.
2) Histamine
Fish stored in poor conditions, such as not refrigerated or frozen immediately after
being caught, may contain a substance called “histamine.” Extra caution is needed forlean fish such as tuna, horse mackerel, sardines, and mackerel. Eating fish or dishes
containing histamine causes allergic reactions. This is called “histamine poisoning.” Ashistamine increases in a poor storage environment, it is necessary to refrigerate or
freeze the fish immediately after receiving it as an ingredient.

-9©OTAFF

3) Solanine
Potato sprouts and green skins contain a substance called “solanine.” Eating foods
containing solanine causes symptoms of food poisoning, such as nausea, vomiting,diarrhea, abdominal pain, and headache. You can prevent them by removing potato
sprouts and green skin parts.
(3)

Biological hazard

Among the hazards, bacteria, viruses, parasites, and molds that cause food poisoning
are called “biological hazards.”
Among biological hazards, bacteria and viruses that cause diseases are also called“pathogenic microorganisms.” Microorganisms are small creatures such as bacteria
and viruses that cannot be seen without a microscope.
1) Bacteria (food poisoning bacteria)
Among pathogenic microorganisms, bacteria that cause food poisoning are called“food poisoning bacteria.”- 10 ©OTAFF Typical food poisoning bacteria and their symptoms
Name of foodpoisoning bacteria

FeatureFood likely to cause

Main symptoms

Campylobacter spp. Increases in the body andcauses illness.

Meat (especially chicken)

Diarrhea, abdominal
pain, fever

Salmonella spp.

Increases in the body andcauses illness.

Eggs and meat (especially Diarrhea, abdominal
chicken)pain, fever

Vibrioparahaemolyticus

Increases in the body andmakes toxins.

Seafood

Abdominal pain,
severe diarrhea

Enterohemorrhagic
E. coli(O157, O111, etc.)

Increases in the body andcauses illness. Some
produce toxins.

Meat (especially beef),
vegetables, well water

Abdominal pain,
severe diarrhea,
bloody stool

Staphylococcus
aureusExists in a person’s skin or Rice balls, sandwiches,wound.
etc.
Increases in food andmakes heat-resistanttoxins.

Nausea, vomiting,abdominal pain

Bacillus cereus

Produces heat-resistantspores (*).
Increases in the body andfood and makes toxins.

Processed grains, fried
rice, etc.

Nausea, vomiting,abdominal pain,
diarrhea

Clostridium
perfringens

Produces heat-resistantspores.
Increases in food, andmakes toxins in the body.

Earthy ingredients, water,
cooked foods (curries,
stews, etc.)

Abdominal pain,
diarrhea

Clostridium
botulinum

Produces heat-resistantspores.
Increases in food andmakes toxins.

Bottled foods, retort foods, Nausea,
etc.
dyspnea- 11 ©OTAFF

vomiting,(*) Spore
A spore is like a shelled bacterial species. Normal bacteria die when heated, but somesurvive by producing spores when heat or dryness make it difficult for bacteria to grow.
When the bacteria return to the environment where they grow easily, they start to revert
from spores back to normal bacteria.
The following three principles of food poisoning prevention are important to prevent
bacterial food poisoning.
a) Do not contact microbesb) Do not allow microbes to multiplyc) Kill microbesa) Do not contact microbes
This means avoiding putting food poisoning bacteria on clean food and ingredients. To
do this, wash hands as specified before starting work or when necessary. Also, washand sterilize machines and cooking utensils.
b) Do not allow microbes to multiply
This means not increasing food poisoning bacteria in food. Bacteria need hightemperatures, high humidity, and nutrients to grow. Many bacteria prefer hightemperatures (20°C to 50°C) and high humidity (or moisture). Especially at 30°C to
40°C, they increase rapidly. However, they increase slowly below 10°C, and hardly
increase below 4°C. They do not increase below -15°C. It is important to store food ata low temperature in order not to increase food poisoning bacteria in food.
Some food poisoning bacteria make toxins. These toxins can also cause foodpoisoning. Some toxins produced by Staphylococcus aureus, Bacillus cereus, andothers cannot be destroyed even when heated. Therefore, for these food poisoning
bacteria, it is especially important not to let them increase or make toxins.

- 12 ©OTAFF

c) Kill microbes
This means killing food poisoning bacteria in ingredients and food. When sterilizing byheating, it is important to heat for a specified time at a specified temperature. Many
food poisoning bacteria can be killed by heating at 75°C for at least 1 minute, but more
stringent conditions may be needed to kill the spores. When sterilizing with chemicals,
it is important to sterilize the whole food for a specified time with a specified
concentration of agent.
Some spores may not be destroyed (killed) by cooking alone, and Bacillus cereus andClostridium perfringens may increase as the temperature slowly decreases after
cooking. For this reason, it is important to cool the cooked food immediately.
2) Virus
A typical virus that causes food poisoning is norovirus. Bivalves such as oysters may
be contaminated with norovirus. Norovirus does not increase in food, but it increases
in the infected person’s body (intestine), causing symptoms such as abdominal pain,
diarrhea, and vomiting. Norovirus is in human feces and vomit.
The basic measure to prevent food from being contaminated with norovirus is to wash
hands thoroughly. Especially, washing hands after going to the bathroom is important.
To kill norovirus by heating, ingredients and food must be heated at least 90 seconds
after their center temperature reaches 85°C to 90°C.
Alcohol disinfectant cannot kill norovirus. The machines and utensils used to cookshould be washed and soaked in a sodium hypochlorite solution with a concentrationof 200 ppm (parts per million) or wiped with a cloth soaked in a sodium hypochlorite
solution.

- 13 ©OTAFF

(*) Four principles of food poisoning prevention caused by norovirus
Norovirus does not increase in food. For this reason, “do not allow microbes to multiply”
among the three principles of food poisoning prevention is not effective.
To prevent food poisoning caused by norovirus, it is important “not to bring” norovirus
into food manufacturing plants. Before entering a food manufacturing plant, workers
should make sure they are not infected with norovirus, and wash their hands thoroughly.
When a worker is infected with norovirus, it is important to thoroughly disinfect theinside of a food manufacturing plant. Vomit should be handled correctly using
specialized equipment. This is called “not to spread.”To prevent food poisoning caused by norovirus, the following four principles areimportant: 1) Do not bring it, 2) Do not contact it, 3) Kill it, and 4) Do not spread it.
3) Mold
Mold is a microorganism, but it can grow and become visible. Mold spores are
everywhere and cannot be fully eliminated. Beans, grains, vegetables, and fruits arefoods that tend to increase mold during storage. Don’t use moldy food.
4) Parasite
Parasites live on the surface and inside the bodies of people and animals by taking
nutrients from people and animals. For example, there is a parasite called Anisakis.
Anisakis infests fish and shellfish such as mackerel, sardines, salmon, horse mackerel,and squid. Eating raw seafood with Anisakis causes a severe stomachache. This iscalled “Anisakis food poisoning.” Anisakis can be killed by heating above 70°C or for 1
minute at 60°C. It can also be killed by freezing at -20°C for more than 24 hours.

- 14 ©OTAFF

3.

General hygiene control“General hygiene control” refers to hygiene control that is common in all workplaces
when making any food.
It can be divided into three categories: hygiene control of facilities, equipment, andutensils; hygiene control by workers; and hygiene control of ingredients and food. What
all three have in common is the 5S concept.
This section explains (1) 5S, (2) hygiene control of facilities, equipment, and utensils,(3) hygiene control by workers, and (4) hygiene control of ingredients and food.
(1)

5S

The term “5S” refers to five activities (*) beginning with the letter S.
(*) Sorting, Setting-in-order, Shining, Standardizing, and Sustaining/Self-discipline
1) Sorting: Remove what you do not use and keep only what you use. Eliminate
unnecessary utensils and tools and leave only necessary ones.
2) Setting-in-order: Make utensils and tools readily available when needed. To do this,place them in a specific location, arrange them in a convenient order, and display
their names and quantities.
3) Shining: Clean equipment, utensils, and tools by washing, polishing, or wiping
them. Also, remove dirt.
4) Standardizing: The workplace looks good and has no problems with food hygiene
through sorting, setting-in-order, and shining. Equipment and utensils are notcontaminated with pathogenic microorganisms.
5) Sustaining/Self-discipline: Be able to do what is decided as decided. Be able tofollow the rules of sorting, setting-in-order, shining, and standardizing.
General hygiene control is based on the 5S concept, such as keeping facilities,
equipment, and utensils clean, preventing the introduction of pathogenic
microorganisms from workers’ fingers and work clothes, preventing the introduction ofpathogenic microorganisms into ingredients and food, and removing hard foreign
objects.
The 5S concept is useful not only for food hygiene but also for labor safety, which
prevents you from getting sick or injured in the workplace. It is carried out in various
factories and workplaces in Japan and around the world.

- 15 ©OTAFF

(2)Hygiene control of facilities, equipment, and utensils

Ensure that facilities, equipment, and utensils are properly managed to prevent
hazards from entering food by keeping metal fragments or chemicals out of food, andby not allowing pathogenic microorganisms to contact or multiply in food.
Clean people or objects (ingredients, food, machines, utensils, etc.) can becomecontaminated with hazards if they come in contact with people or objects that are notclean. This is called “cross-contamination.” To prevent cross-contamination, it isimportant to properly use facilities, equipment, and utensils for their intended purpose,and to keep them clean.
1) Different uses of facilities and equipment (zoning)
To prevent cross-contamination, food manufacturing plants are usually divided into
clean, semi-clean, and contaminated work areas. This hygiene control by dividing
areas is called “zoning.”
In a clean work area, foods that have been sterilized by heating or chemicals arehandled. For example, in ready-made meal manufacturing, topping, serving, packaging,and other work are done in this area.
In a semi-clean work area, ingredients before sterilization are handled. Preparation,cooking, etc., are carried out. Foods that are being prepared or cooked must not comeinto contact with ingredients before work in this area.
In a contaminated work area, ingredients which brought in from outside the workplace
are received and handled. Products packed in cardboard boxes for shipping are also
handled here.

- 16 ©OTAFF• People working in contaminated work areas must not enter semi-clean or clean work
areas. Ensure that ingredients from contaminated or semi-clean work areas do notpass through clean work areas.
• Ingredients must not be brought into semi-clean or clean work areas in cardboard
boxes or containers. The cardboard boxes and containers may be contaminatedwith dirt, dust, insects, and microorganisms.
• When you take out unnecessary ingredients or garbage from the workplace, take itout by a designated route. Some food manufacturing plants decide the time to use
the passage to take out garbage. After using the passage, clean, wash, and disinfectit to prevent cross-contamination.
2) Cleaning, washing, and disinfection
Facilities and equipment must be cleaned regularly and always kept clean.
If not cleaned, insects and mice may enter and increase in the workplace, resulting ina poor sanitary condition of facilities and equipment.
Extra caution is needed for drains and places under large machines, where insects
tend to infest. Remove covers and wash drains. The floor of the workplace should not
be left wet, because microorganisms increase.
Wash machines such as mixing machines (mixers) and cutting machines (slicers andchoppers) every time after changing ingredients. Make sure to wash them when thework is finished as well. If possible, disassemble and wash the parts. Machines should
be washed every day even if they do not seem dirty.
After washing them thoroughly in this way, parts that directly touch food such as blades
should be sanitized.
If the utensils used for work (kitchen knife, cutting board, etc.) have dirt left,
microorganisms will grow there. Moisture on the utensils can also cause
microorganisms to grow. After using utensils, wash them in a prescribed way and drythem so that no moisture remains before storing them.

- 17 ©OTAFF

If cleaning tools such as scrubbers, sponges, mops, wiping cloths, squeegees, anddeck scrub brushes are left dirty or wet, microorganisms may develop.
3) Management of chemicals
When chemicals are mixed into food, people who eat the food may get sick. Also, if thechemical gets into the eyes or on the skin of the person who manufactures the food,the person may become blind or get burned.
Chemicals must be stored correctly in a designated area. Sanitizing and washing
agents and other chemicals should not be stored in the same storage as ingredients.
Also, they should be labeled with their names so that they can be easily distinguished.
If you find a chemical without a label, you must report it to the person in charge
immediately.
(3)

Hygiene control by workers

Workers should not bring into the workplace anything that causes foreign object
contamination or pathogenic microorganisms that cause food poisoning. In addition,
cross-contamination (see “(2) Hygiene control of facilities, equipment, and utensils”)
from work clothes and workers’ fingers must be prevented. The hygiene control
necessary for this purpose is explained below.
1) Health check
Before starting work, make sure that workers have no symptoms such as diarrhea,
fever, and nausea, or scratches on the fingers. This is called “health check.” Anyone
who has these symptoms must report it to the person in charge. Even though you did
not have any symptoms when you started work, you may get a stomachache or cut
your fingers later. You should not continue working in such case. Stop the work
immediately and report it to the person in charge.
Workers must undergo regular medical checkups and stool examinations as decided
at the workplace.

- 18 ©OTAFF

2) Work clothesa) Wearing work clothes
To avoid bringing dirt and foreign objects into the workplace, and to avoid putting
microorganisms on ingredients, machines, and utensils, the following points must be
followed to properly wear work clothes.
• Wear work clothes in a changing room.
• All work clothes, a face mask, a hair net, a hat, shoes,
and gloves must be clean and fit your size.
• Always cut your nails short. Don’t enter the workplacewith fake nails or nail polish.
• Don’t enter the workplace wearing rings, bracelets,
watches, accessories (e.g. necklaces and earrings),
hairpins, false eyelashes, etc.
• Don’t bring anything into the workplace that is notnecessary for the work.
Check in a mirror that you are wearing the work clothes correctly. For example, makesure that the clothes you are wearing under your work clothes are not visible, the facemask is covering your nose, and your ears and hair are not coming out of the hat orhair net.

- 19 ©OTAFF

Generally, put on work clothes in the following order:i)

Brushing
Brush your hair well.

ii)

Hair net
Wear a hair net.
Put all your hair in.

iii) Hat
Put on a hat.

iv) Work clothes
Put on work clothes.
Fasten buttons and zippers properly.

v) Check
Finally, check if you are wearing the clothes properly.

Work clothes must always be worn correctly during work. For example, you should nottake off your hat just because the workplace is hot. Don’t roll up the sleeves of yourwork clothes. Don’t take off your face mask either.

- 20 ©OTAFF

Before entering the workplace, remove hair and dust from work clothes with anadhesive roller or air shower.
Adhesive roller

Air showerb) Zoning and work clothes
Don’t leave the workplace with your work clothes, hat, or shoes. If you go back to theworkplace, you end up bringing dirt, dust, insects, and microorganisms on your work
clothes, hat, and shoes into the workplace.
You must change into toilet footwear in a bathroom.

- 21 ©OTAFFWork clothes
Wear a hair net
under a hat.
The collar is a Mandarin
collar, to which hair anddust are hard to attach.
Wear a T-shirt or
unbuttoned clothes
under the working
jacket.

Work clothes should
not have pockets or
buttons.

Wear clean work
clothes.

Sleeves and hemsof work clothes
are squeezed withrubber bands.

Tuck in a jacket andshirttail wearing under thejacket in your pants.

Wear clean shoes.

Apron

Arm covers- 22 ©OTAFFWith an apron and arm
covers over work clothesPrecautions for properly wearing work clothes, hats,and face masks

You are wearing a hatlow.
All your hair is in thehat.
Tie up if you
have long hair.

A face mask iscovering fromyour nose tochin.

The hem of a
hat is put inthe jacket.
The zipper goes
all the way up.

The wire of a facemask fits your noseso there is no gap
between your noseand the mask.

All your hair is in the
hat.
Don’t make gaps
between your cheeks
and face mask.
Tie up if you havelong hair.

The face mask iscovering up to yourchin.

Precautions for properly wearing gloves
Proper wearing

It fits your hand size.

Incorrect wearing

It does not fit your handsize.

- 23 ©OTAFF

There are tears or dirt.

3) Hand washing
Wash hands to avoid contaminating ingredients and food with microorganisms on yourfingers. Hands should be washed in the following cases:• Before entering the workplace• Just before starting work in the workplace• After going to the bathroom• When touching food or utensils after touching raw meat, fish, eggs, etc.
• Before directly touching food, such as for serving• When moving from a contaminated work area to a non-contaminated work area

- 24 ©OTAFF

Proper hand-washing method
A. Clean hands well with running water.

B. Soap hands, fingers, and wrists.
Especially, wash the area between thefingers, and the tips of the fingers andnails.
(About 30 seconds)

A

B

C. Rinse the soap well with running water.
(About 20 seconds)

C

D. Dry your hands with a disposable paper
towel or a hand dryer.

D

E. Spray rubbing alcohol on both hands andrub it into them.

E- 25 ©OTAFF

4) Wearing and replacing gloves and aprons
Gloves and aprons are used in food production work to prevent workers from exposing
ingredients and food to hazards. Disposable gloves and aprons are often used toensure thorough hygiene control.
Wash hands before wearing gloves.
Gloves should be replaced to avoid contamination of ingredients and food in thefollowing cases:• When you change ingredients to be handled, such as when cooking vegetables after
meat or fish. This is to prevent hazards (pathogenic microorganisms and allergic
substances) of the ingredients handled earlier from being applied to the next
ingredients.
• When you start food production work after touching a cardboard box or container toreceive ingredients• When you enter the workplace after going to the bathroom or taking a break• When you touch sterilized ingredients (cooked or uncooked)• When the gloves you were wearing are torn
• When you start serving food after another food5) What workers must observe• Before the work, read the operating procedures and confirm where and what work
you should do. Check the machines, equipment, and utensils to be used for dirt anddefects.
• Don’t eat or drink anything in the workplace. Don’t smoke. Don’t spit. Don’t blow
your nose or cough near food.
• Don’t work with hands that have touched your hair, eyes, nose, or around yourmouth. If you do, wash your hands again or change your gloves.
• Don’t wipe your hands on your work clothes.
• Don’t bring any non-work-related belongings (watches, smartphones, wallets,
photos, cigarettes, etc.) into the workplace.
• Don’t bring paper with staples or clips, pencils, or mechanical pencils into theworkplace. This is because staples, clips, broken pencils, and mechanical pencil
lead can cause foreign object contamination.

- 26 ©OTAFFAn odor itself is not a hazard, but it has a bad effect on the quality of food. For thisreason, you should not bring anything that smells strong, such as perfume, into theworkplace. Some food manufacturing plants even prohibit workers from using perfume,
because they may not notice that the quality of ingredients or food has deteriorated ifthey wear perfume.
Some food manufacturing plants adopt work clothes without pockets. This is to prevent
workers from intentionally bringing items into the workplace that are not used in thework. To make sure that the work is done correctly, some plants record the comings
and goings of the workers or place cameras in the doorway or warehouse of theworkplace.
(4)

Hygiene control of ingredients and foodTo produce safe and quality food, it is important to use safe and quality ingredients andto control the manufacturing method properly.
1) Acceptance and storage of ingredientsa) Acceptance of ingredients
When accepting ingredients from outside, check the ingredients you received against
the order form to make sure the contents are delivered correctly. This is called“acceptance inspection.”
Check the appearance and smell of ingredients, standards (size and number ofingredients), packaging conditions, labeling of expiration date and storage method,
product temperature, etc. Don’t accept items that are spoiled, have broken packaging,have expired, or are not properly stored. In such case, report it to the person in charge
and return or exchange the item.

- 27 ©OTAFFFor the ingredients subject to acceptance inspection, they are accepted after
confirming that they have passed the inspection.
When accepting ingredients that need to be refrigerated or frozen, avoid leaving themat room temperature for long periods of time.

- 28 ©OTAFFb) Storage of ingredients
Storage of ingredients depends on the type of ingredients. Each ingredient must be
stored at a specified temperature. Storage temperatures of the main ingredients are
as follows:
Type of ingredientTemperature

Rice

15°C or lessProcessed grains (wheat flour, starch)

Room temperature(Note 1)

Seasoning (sugar, salt, miso, soy sauce and other sauce,vinegar)Room temperature

Meat

10°C or lessMeat products (ham, sausage, bacon)

10°C or lessFrozen meat

-15°C or lessFrozen meat products-15°C or less

Boiled octopus

10°C or less

Fresh seafood

5°C or lessFrozen fish

-18°C or lessFrozen food

-18°C or lessLiquid fats

Room temperature

Solid fats (lard, margarine, shortening)

10°C or less

Eggs in the shell

10°C or lessLiquid eggs

8°C or lessFrozen eggs

-18°C or less

Fresh fruits and vegetables (Note 2)

Around 10°C

Milk, concentrated milk, skim milk, cream

10°C or lessButter, cheese, condensed milk

15°C or less

(Note 1)

Store in a dry place at room temperature.

(Note 2)

Storage temperature may be specified for some pre-cut vegetables incontainers.

- 29 ©OTAFF

Don’t fill a refrigerator with ingredients. Without gaps, cold air cannot circulate
throughout the refrigerator to cool the ingredients sufficiently. In the case of a freezer,
it is better to fill 80 to 90% of the freezer with frozen foods so that they can cool eachother and save electricity. Don’t leave the refrigerator or freezer door open, because it
will not keep the temperature low.
Periodically measure the temperature in the refrigerator and freezer to make sure theright temperature is kept every day, and record the results.
The Food Sanitation Act stipulates that freezers be set at -15°C or less andrefrigerators at 10°C or less.
Keep the inside clean by regularly cleaning shelves and floors in the refrigerator andfreezer.
c) Use-by date, best-before date, and expiration date“Use-by date” is the last day of the period when ingredients are allowed to be used.
Don’t use ingredients that have passed their use-by date. Each ingredient has adifferent use-by date. The food manufacturing plant that uses the ingredient decides
the use-by date.
If the ingredient is processed food in a container or bag, the best-before date or
expiration date is indicated on the container or bag. The company that manufactured
the processed food (ingredient) indicates both dates.
“Best-before date” is the last day of the period when unopened processed food can beeaten deliciously if stored under specified conditions. You can eat food that has passed
the date, but food manufacturing plants generally do not use food (ingredients) thathave passed their best-before date.

- 30 ©OTAFF

“Expiration date” is the last day of the period when unopened processed food can beeaten or used if stored under specified conditions. Food (ingredients) that have passed
the expiration date are more likely to cause food poisoning, so never use them.
Ingredients delivered (received) first are used first. This is called “first-in, first-out.”
Generally, the best-before date or the expiration date comes first for the item delivered(received) first.
2) Opening and preparation of ingredientsa) Opening
When you open packages, take care not to accidentally allow the packaging materials
to enter into the product, such as cardboard boxes, kraft and other paper, plastic
baskets containing vegetables, and plastic bags containing frozen meat.
(*) To prevent scraps of opened bags and containers from entering into food• Don’t cut the same place more than once.
• Make sure that the cut ends are aligned with the cut ends.
• Check that the number of opened bags and containers and the number of scraps
are the same.
b) Preparation
 Thawing and heating

Frozen ingredients can be thawed at room temperature (“room temperature thawing”),
in a refrigerator (“refrigerator thawing”), or with tap water (“running water thawing”).
When thawing, the meat or fish is placed in a tray to prevent the juice (“purge”) fromcontacting other food or ingredients. It may be placed on a mesh tray and placed in athawing rack to allow the purge to flow directly into a drain.

- 31 ©OTAFFWhen thawing under running water, before thawing, make sure there are no holes ortears in the airtight bag that holds the ingredient. If there are holes or tears in the bag,some of the ingredients will flow out with the running water. If you find holes or tears,transfer the ingredient to another airtight bag before thawing.
Solid fats and food pastes are easier to take out from the container when heated andsoftened. Careful control is required when heating ingredients, as overheating candeteriorate their quality.
 Washing

Many ingredients are washed with water to remove foreign objects and dirt. In the caseof seafood and algae, they may be washed with a salt solution of appropriate
concentration. Ingredients such as vegetable salads that do not have a heatingprocess are sterilized using chemicals.
 Selecting, sorting, and cutting

Ingredients that have dirt, a different color, texture, or smell as well as the parts suchas vegetable roots, sprouts, skins, fish scales, and fins are not used. These should be
removed and disposed of to prevent them from being used in food production.
For raw meat, the X-ray foreign object detector may be used to check whether there
are any bones left in the meat. Remove any bone if found.
3) Hygiene control of manufacturing processa) Washing manufacturing equipment
Equipment used for food production, such as shredding, mixing, heating, and molding,must be washed and cleaned. If water remains in the production facility or in the pipingthat leads to the production facility, the water may be contaminated withmicroorganisms. Therefore, wash the production facility again or flush the remaining
water from the piping with hot or cold water.
When food containing allergic substances is manufactured, the equipment used is
carefully washed so that no allergic substances remain in the equipment. Foodcontaining allergic substances may be produced at the end of the day and thencarefully washed.

- 32 ©OTAFFb) Heat sterilization
Heating can make ingredients easier to eat and digest, and more delicious. In addition,
proper heating can eliminate the biological hazards (such as pathogenic
microorganisms) contained in the ingredient. This is called “heat sterilization.”
Some microorganisms among bacteria, such as spore-forming bacteria (*), are heat
resistant and do not die even above 100°C. Therefore, when killing microorganisms byheating, the temperature and time of heating must be set appropriately.
(*) Bacteria that produce spores, such as Bacillus cereus, Clostridium perfringens, andClostridium botulinum
Example of heating temperature and time to kill microorganisms
Spore-forming bacteria such as
Bacillus cereus

Center temperature 120°C

4 minutes or
more

Norovirus

Center temperature 85°C to
90°C

90 seconds or
more

Common food poisoning
bacteria

Center temperature 75°C

1 minute or
more

Heat sterilization must be controlled at the center temperature of the ingredient. When
heating large ingredients such as block meats, the center temperature should always
be checked.
c)Cooling after heat sterilization

Many pathogenic microorganisms can be killed by heat sterilization. However, you
cannot kill them all at once, because some of them will survive even after heated. Somewill increase in the food while the heated food cools slowly, and cause food poisoning.
For this reason, it is important to cool the cooked food immediately.

- 33 ©OTAFF

Specifically, the center temperature must be reduced to 20°C within 30 minutes or to
10°C within 60 minutes after heating.
There are two cooling methods: air (“air cooling”) and cold water (“water cooling”).
It is also important to cool the finished food immediately so that the taste is not spoiled.
d) Chemical sterilization
Chemicals may be used to kill pathogenic
microorganisms in unheated foods. This is called“chemical sterilization.” Chemical concentration andtreatment time are key.
Specifically, the food is soaked in a sodium hypochlorite
solution with a concentration of 200 ppm for 5 minutes,
or 100 ppm for 10 minutes.
e) Freezing
Fresh and processed foods are cooled and frozen to
improve their shelf life. Freezers are used to freeze food and store frozen food.
If food is frozen slowly, the texture and flavor such as hardness and chewiness will
deteriorate. For this reason, it is necessary to freeze food quickly in a short period oftime in order to freeze food deliciously.
4) Filling, packaging, and inspection
Food that has sufficiently reduced hazards through sorting and sterilization are filled or
packaged in clean containers. This is to prevent hazards from coming in from outside.
Containers and packaging materials used for filling and packaging, such as bottles,
caps, and bags, must be clean. Especially, don’t touch the mouth of the bottle, the cap,or the inside of the bag.

- 34 ©OTAFFThe best-before and expiration dates are correctly printed on the containers andpackaging of processed foods to be shipped.
Many mistakes have been made, such as wrong best-before date or expiration date.
Different people should check that the settings of the printing machine are correct andthat the printed dates are correct.
After filling or packaging, the container or package may be inspected to make sure if
there are small holes that allows air to leak in or out, or contents to leak out.
a) Metal detector
If there is a possibility of metal contamination in food,a metal detector may be used for inspection. This isbecause it can find metal among hard foreign
objects.

Image credit: Ishida Co., Ltd.
The important thing in managing a metal detector is to use a test piece to make surethat the metal is detected correctly before you start checking for contamination withforeign objects. When production is finished, use the test piece again to verify that themetal detector was functioning properly until the end. The size of the test piece isdetermined by each food manufacturing plant.
If the metal detector does not function properly, you must report it to the person in
charge immediately. This is because any food that has been made from the time you
made sure the metal detector was working correctly to the time it is not working rightmight have metal in it.

- 35 ©OTAFFb) X-ray foreign object detector
An X-ray foreign object detector can detect hard foreign objects
such as stone and glass that cannot be found by metal detectors.
It is sometimes used to control the receipt of ingredients and tocheck for insufficient quantity of products or defective shapes.
Plastic is hard to find by X-rays, so instead of relying on X-ray
foreign object detectors, you must make sure that plastic does
not get into food from machines and equipment.

Image credit: Ishida Co., Ltd.
c) Microbiological examination
Foods that are obligated by law for microbiological examination are tested for the
specified items in a specified way. In a voluntary microbiological examination
conducted by a food manufacturer, the general viable count, Escherichia coli, andcoliform bacteria are generally tested. Staphylococcus aureus, Salmonella spp., andCampylobacter spp. may also be tested.
5) Storage, Shipping, and Delivery
Food that passed the inspection is stored in the product warehouse until shipment.
Storage temperature and other conditions are determined for each food.
a) Storage of product samples
If you receive a complaint about a product that has been shipped, you need to find out
if there is a similar problem with the products that were manufactured during the same
period. To do this, a certain percentage of products are extracted and stored as
samples.
b) Shipping and delivery
Foods stored in the product warehouse first are shipped first. This is also “first-in, firstout.” (See “(1) Acceptance and storing ingredients.”)
They are transported at a temperature determined for each food so that the quality
does not deteriorate during transportation.

- 36 ©OTAFF

4.

Hygiene control by HACCP

Some foods cannot be manufactured free of hazards by general hygiene control alone.
Such foods require not only general hygiene control but also a special system to ensurethat they do not have their hazards.
1) Examine food ingredients and manufacturing processes to analyze what hazards
exist and how they can be controlled to make food hazard free (“hazard analysis”).
2) The most critical process (“critical control point [CCP]”) and the criteria for
managing the process (“management standard”) are determined.
3) Monitor that general hygiene control is performed and the critical control point is
controlled properly. If they are not conducted correctly, the food will not be shipped.
In this way, ensure that foods are produced with no hazards. This system is called“hygiene control by HACCP.”
Some foods have more than one critical control point.
(1)

Seven principles of HACCP

HACCP operates according to the following seven principles of HACCP:
Principle 1: Hazard analysis
Analyze the hazards to determine what controls are required to ensure that the food tobe produced does not contain a hazard.

- 37 ©OTAFF

Principle 2: Determining critical control point
As a result of Principle 1, if general hygiene control alone is not sufficient to produce
food that does not contain a hazard, a critical control point should be determined toeliminate the hazard.
Principle 3: Setting management standard
Determine the management standard for the critical control point.
Principle 4: Configuring monitoring methods
Determine how to monitor the management status of the critical control point.
Principle 5: Establishing remedial actions
In case a critical control point deviates from the management standard, decide actions
to be taken to meet the standard and handling of the food that has been made.
Principle 6: Configuring validation methods
Confirm that the measures determined in Principle 5 are effective in eliminating andreducing hazards.
In addition, determine how to confirm that the measures determined in Principle 5 has
been implemented as planned.
Principle 7: Recording
Record the contents of Principles 1 through 6 in writing. Also, record the results ofactual confirmation using the method determined in Principle 6.
(2)

Critical control point and management standard

Many foods need to be managed with critical control points. The points depend on the
food. For example, in the case of ready-made meals, the points of processes differ
depending on whether the food is cooked or uncooked.

- 38 ©OTAFF

Management standards must be observed for critical control points.
The following five processes are typical critical control points in food production.
Specifically, see “Section 3. General hygiene control” in this chapter.
1) Heat sterilization
2) Cooling after heat sterilization
3) Chemical sterilization
4) Metal detector
5) X-ray foreign object detector(3)

Deviation from management standard“Deviation from management standard” is defined as cases where the specified
management standard is not actually observed, such as cases where the food isdetermined to be heated for 1 minute or more after the center temperature reached
75°C, but actually the temperature reached only 70°C, or cases where the food isdetermined to be soaked in 100 ppm sterilization solution for 10 minutes for sterilization,
but actually soaked for only 5 minutes.
If you notice that a critical control point has deviated from the management standard,
you must report it to the person in charge immediately.
In that case, you should take the following remedial actions to ensure that no hazards
remain in the food. Follow the instructions of the person in charge when taking remedialactions.
(4)

Remedial action

Make sure that the critical control point will not be deviated from the same management
standard again. Also, decide handling of the food that has already been made (disposal,
remanufacturing, or other actions). These two necessary measures are called“remedial actions.”- 39 ©OTAFFFor example:
If the speed of the conveyor through the heating zone was too fast and the center
temperature of the food was not high enough, adjusting the speed of the conveyor toslow down and discarding the underheated items are considered remedial actions.
If the metal detector was not functioning properly, adjusting the machine to function
properly and then inspecting the food again are remedial actions.
(5)

Recording

It is necessary to keep records of how HACCP was implemented, such as the
management records of the critical control points implemented, and the remedialactions taken when deviating from the management standards. Records can verify thatthe food was produced with appropriate control measures toeliminate hazards.
In both general hygiene control and critical control points,
procedures for when, by whom, and how to record must be
determined in advance.
For example, decide when, by whom, and how to record thetemperature in the refrigerator, the center temperature ofheated hamburger steaks, and the concentration of thesterilization solution used.
You must record the temperature, concentration, and time as soon as you measure orcheck it. Don’t record all at once later. Don’t record the results before measuring justbecause they are always the same. Don’t record without checking.
Never record something that is not true. Don’t correct the results by your judgment.

- 40 ©OTAFF

Chapter 3: Labor Safety- 41 ©OTAFF

1.

Industrial accidents in the manufacture of food and beverages(1)

Relationship between experience and industrial accidents

Among all manufacturing industries, the highest number of unskilled workers (thosewith less than three years of experience) are killed or injured in the food processing
industry. In the workplace of manufacture of food and beverages, it is important to work
carefully so that industrial accidents do not occur.
Unskilled workers account for about half of all industrial accidents in the foodprocessing industry. There are many dangers in the workplace, but especially those
who have little experience and are not used to working can hardly notice them.
Therefore, unskilled workers tend to suffer more industrial accidents than those whohave worked long in the industry.
(See “For Work Safety and Health: To those working in the manufacturing industry” by
Japan Association of Safety and Health Consultants.)
In food manufacturing plants, themost common types of industrial
accidents are: 1) falls on the samelevel, 2) caught in or in between,
and 3) cuts and scratches. These
three accounts for about 60% of allindustrial accidents.

Occurrence of injuries and deaths caused by type of accident
within the food processing industry (2022)

Others30.3%

Falls on the same
level
31.3%

(See pie chart at right.)
Falls fromheight
8.4%

Cuts/
Scratches
10.8%

Caught in or in
between
19.2%(Source: The Ministry of Health, Labour and Welfare website, “Occurrence of
injuries and deaths caused by type of accident by industry (2022)”)- 42 ©OTAFF

(2)Major industrial accidents

1) “Falls” accident
It happens when workers run and slip, trip on things, or cannot walk straight withpackages. As a result, they hit their head or back, or break their hand when landing on
the hand.
2) “Caught in or in between” accident
It happens when workers put their hand in a machine or when they are cleaning
conveyor gears, etc. As a result, it can lead to finger fractures, or in the case of a large
machine, serious accidents such as broken arms or death because the body is caught
in the machine.
3) “Cuts/Scratches” accident
It happens when workers use a knife, a chopper, and other cutting machines, or when
they put their hand into the machine because the ingredients are stuck in. They may
cut their hand or cut off their finger.
4) “Falling” accident
It happens when workers are walking downstairs or working at a high place using aladder or stepladder. They may sprain their foot, hit their body, or break their handwhen landing on the hand.
5) “Burn” accident
It happens when workers are using a machine such as an oven, or when they arehandling hot water or food. They may burn their hands and feet as well as face andwhole body.

- 43 ©OTAFF

6) “Lower back pain” accident
It happens when workers lift heavy things or carry heavy things repeatedly. In the caseof back pain, it may take time to heal, or the same accident may occur repeatedly.
7) “Heatstroke” accident
It happens when workers work for a long time in a place with high temperature andhumidity. The rise in body temperature leads to an imbalance of the water and sodium
levels in the body, which cannot regulate the body temperature well, resulting in death.
8) “Crash” accident
It happens when workers collide with a moving forklift. If a forklift is moving fast, theworker may die.
2.

Important things to be followed for no industrial accident

Workers must follow the instructions of the person in charge and follow the specified
rules. Also, participate in workplace activities aimed at eliminating industrial accidents.
To eliminate industrial accidents, the following are important:
(1)

5S

(2)

Proper attire(3)

Follow operating procedures and rules(4)

Use machines correctly(5)

Use detergents and chemicals with caution

(1)

5S

Even when you are busy at work, it is important to keep the workplace always in thesame condition and take care of yourself and the people around you. The 5S learnedin “Chapter 2: Food Hygiene” are important activities to prevent industrial accidents.

- 44 ©OTAFFa) Sorting, setting-in-order, and shining
Keep the workplace free of unnecessary items (sorting).
It is easier to work by deciding where to put tools, ingredients, etc., and having
everyone move in the same way (“traffic line”). Place the box or pallet in a definedframe or along the tape on the floor (setting-in-order).
This reduces the risk of a fall accident.
Keep equipment and machines always in good condition (shining).
This reduces the possibility of sudden breakdowns in equipment and machines,
thereby preventing industrial accidents such as caught in between.
b) Standardizing
This is useful not only for preventing food poisoning but also for preventing infection ofworkers.
c) Sustaining/Self-discipline
This allows workers to work in a workplace in the same condition every day. It leads topreventing industrial accidents, because they can work without worry.
(2)

Proper attire

To prevent industrial accidents, you must work in proper clothes.
1) Proper wearing of work clothes• When working, wear a set safe clothing (work clothes).
• Wear work clothes that are easy to move in and fit your body size.
• For work clothes with long sleeves, button the cuffs and work without rolling up thesleeves.

- 45 ©OTAFF

2) Proper wearing of safety protective equipment
If you are instructed to wear safety protective equipment, you must wear it properly.
The following are the safety protective equipment often used in food manufacturing
plants.
HelmetHead injury prevention

Safety glasses

Wear when working at aheight of 2 meters or more.

Rubber gloves

Wear when handlingchemicals and fine powder toprevent liquid or powder fromentering the eyes. Also, wear
during high-pressure washingwork to prevent cleaningmaterials from getting into theeyes.

Burn prevention

Earplugs

Wear when handling hot
items and chemicals. Don’t
put your hands in a hot liquid
when wearing them. The
liquid enters through the
opening of the glove and yourhands get burned.
Mitten gloves

Made of heat-resistant clothand rubber. Wear whentouching hot objects.

Mexcel gloves

Prevention of finger cuts

Prevention of finger cuts

Burn prevention
Made of heat-resistant clothand rubber. Wear whentouching hot objects andchemicals, cleaning work, etc.

Safety shoes

Prevention of stress andwounds on the feet
Attached steel plates orplastic plates to the toes andheels to prevent injury.

A kind of cut-resistant glove,
laced with hard-to-cut fibers.
Wear when handling a knife.

Stainless-steel
glovesSoundproofing
Wear in a noisy place toprevent hearing loss.

Heat-resistantapron

Burn prevention

Eye injury prevention

Boot with cover

A kind of cut-resistant glove,
made of stainless-steel
netting. Wear when cutting
meat and hard vegetables(such as pumpkin) with strong
force.

- 46 ©OTAFF

Slip and burn prevention
Oil-resistant and non-slip
soles are used. A coverprevents water from comingin from the top.

(3)Follow operating procedures and rules

1) Follow operating procedures
The operating procedures describe what you must do to prevent industrial accidents.
To prevent industrial accidents, you must follow what is written in the operatingprocedures.
2) Follow basic workplace rules
Rules of the workplace• Don’t run in the workplace.
• Walk down the designated passage and observe theway to cross the passage.
• When a forklift goes by, make eye contact with thedriver and check while walking.
• Don’t go under the conveyor.
• Don’t run down or up stairs.
Rules for working• Follow the procedure of the work.
• Before the work or turning on the machine, checkwith finger pointing and calling (*).
• Communicate and give signals when working withother workers.
• Work without looking away or chatting.
• Place knives and other tools in a designated place
in a designated manner.
• If a dangerous point is found, report it to the person in charge immediately.
• If other workers are doing dangerous work, warn them not to do it.
• When leaving the workplace, speak to the person in charge before leaving.

- 47 ©OTAFF

(*) Finger pointing and calling
While pointing at a signal, sign, utensil, work object, etc.,
say its name and condition aloud. This is done for the
purpose of avoiding danger and confirming safety.

Temperature good!

3) Work with understanding the meanings of safety signs
Safety signs are easy to see and make it easy to understand things that workers should
do and be careful about so that they do not get injured at work. In the workplace, youmust understand the meanings of the safety signs and be careful not to cause injury
or accident.
(*) For safety signs, see the Supplementary Materials.
(4)

Use machines correctly

Major industrial accidents often occur when using machines. When you use a machine,
you must work carefully and calmly.
1)

Use a machine with an understanding of operating procedures

Understand operating procedures correctly and work with the machine. When two
people work with a machine, always communicate with each other to work. If there are
not enough people for the task, don’t do it.
2) Conduct a pre-commencement inspection
Before starting work with equipment and machines, check that there is no abnormality,
as follows.
This is called “pre-commencement inspection” and is an important task for stable daily
production.
• Is there any dirt or anything stuck in it?

- 48 ©OTAFF• Does it smell strange?
• Is there any unusual sound or vibration?
• Is the cutter or slicer chipped?
• Are parts, equipment, and machines that are not supposed to move still?
• Are there any missing bolts, screws, or other parts?
• Does the safety device, whose operation is to be checked in the pre-commencement
inspection, work normally?
• Can the lamp be turned on and off normally?
3) Comply with response to abnormalities
When a machine stops due to trouble, it is necessary to resolve the problem. If you
take the wrong measures, it will lead to a serious industrial accident. Therefore, youmust be careful.
a) Keep your hand away from a machine while the power switch is on (operating)
Never put your hand into an operating machine. Especially, a machine that is stuckwith an object seems stopped, but the cutting edge or the screw may be rotating inside.
There have been many accidents in which the machine starts to move, and workers’
hands get caught when the stuck object is removed. Again, keep your hand away froman operating machine.
Also, you should never put your hand into a machine that is operating slowly, because
it has a strong moving force and may not stop even if you get caught in it.
b) Use an emergency stop button
A control panel has an emergency stop button.
When you press the button, the machine stops
immediately. When something unusual happens,
the most important thing is to stop the machine
first.

- 49 ©OTAFFc) Use a safety device
For machines with a safety device (fail-safe*), the machine stops automatically when
the door is opened. You can resolve the problem while stopped. You must use themechanism of this safety device when you work.
(*) Fail-safe“Fail-safe” is a mechanism by which the machine stops automatically when a part
breaks or a product is stuck. A safety device attached to a machine is also a fail-safe
mechanism to avoid touching the operating machine by mistake.
d) Always turn off the power switch when repairing a conveyor.
A safety cover (foolproof*) is attached to a rotating part of conveyor chain and gear.
This prevents workers from putting their hand in the machine by mistake. Many
disasters have occurred because they worked with this cover off without turning off thepower switch. Also, to prevent other workers from turning on the power switch again,
hang a sign such as “Machine Under Repair” over the power switch to work safely.
(*) Foolproof“Foolproof” is a system designed to prevent disasters even when people accidentally
do or misunderstand something. A safety cover is a foolproof mechanism to keep
workers’ hands away.
4) Keep machines working properly by inspection and maintenanceInspection and maintenance are very important for stable operation of machines andto prevent accidents. Make sure to plan for inspections and maintenance even if the
production is busy, as they cannot be skipped. The following three points are important:• Display “under inspection and maintenance” on the operation panel of the machineso that others can see it.
• Lock the power switch to prevent the machine from working.
• Check safety devices as well.

- 50 ©OTAFF

(5)Use detergents and chemicals with caution

Keep the following points in mind when using detergents and chemicals:• To prevent detergents and chemicals from getting into your eyes or onto your hands,
wear safety protective equipment such as safety glasses, gloves, and aprons.
• Always put the safety protective equipment in a handy place.
• Mixing chlorinated detergent and acid detergent for use is dangerous, because theygenerate toxic chlorine gas. Follow the rule of using detergent.
• Rubbing alcohol should not be placed near machines that get hot, such as ovens
and air fryers, because alcohol may catch fire.
3.

Response to abnormal situations or industrial accidents(1)

When an abnormal situation occurs

If you notice any abnormalities, take the following actions:
1) Check what is happening and let the person in charge and workers around you
know loudly.
2) When you can judge by yourself, stop the machine operation by pressing the
emergency stop button, etc., as necessary.
3) Follow the instructions of the person in charge. Don’t act on your own.
(2)

When an industrial accident occurs

In the event of an industrial accident (when you find an injured or fallen person), don’t
run toward them. It is because the person who tried to help may also be another victim.
This is called a “secondary accident.” The first step you should take is the same as for“(1) When an abnormal situation occurs.”- 51 ©OTAFF

1) Check what is happening and let the person in charge and workers around you
know loudly.
2) When you can judge by yourself, stop the machine operation by pressing the
emergency stop button, etc., as necessary.
3) Follow the instructions of the person in charge. Don’t act on your own.
It is important to conduct a drill on a daily basis in order to act properly when abnormal
situations or industrial accidents occur. Regularly conduct evacuation drills for fire andother disasters as well as drills for pressing the emergency stop button.

It smells strange.
The lever is loose.

It’s making a strange
noise.

The red lamp is on.

The blue lamp is off.

xxx is missing.
It was hot when I
touched it.
The lamp is flashing.

- 52 ©OTAFF

4.

Build awareness of danger

It is important for unskilled workers to develop an ability to notice dangers to prevent
industrial accidents. Learn this ability, and if you notice any danger at the workplace,report it to the person in charge.
(1)

Learn about cases of industrial accidents

It is very important to know cases of industrial accidents in the manufacture of foodand beverages. You should learn well the cases introduced in the company and work
carefully so that you do not cause or suffer from the same accident.
1) Know cases of industrial accidents in the company
Cases of industrial accidents in the company are the most important cases that arefamiliar and easy to understand for people who do the same work with the sameequipment. Therefore, learn and remember them well.
2) Learn about cases of industrial accidents outside the company
Cases of industrial accidents outside the company may also be introduced. It is usefulto learn about the cases to prevent the same accident from happening, because there
can be the same danger in the company. Learn well and be careful not to let the same
accident happen in your work.
(2)

Participate in near-miss activities

There is a case that a worker almost got injured whileworking. This is called a “near miss.”
There is a theory that before one serious industrial accident
occurs, 29 minor injuries or accidents and 300 near missesthat did not result in injury or accident occur due to the samecause. This is called the “accident triangle.”

Accident triangle

From the accident triangle, fewer near misses will lead to
fewer serious industrial accidents.

Minor accidents

Serious accidents

Near misses- 53 ©OTAFFFor this purpose, all the workers and the people in charge in the factory report theirnear misses to each other and record and share them, so that everyone can think
about the cause of the near misses and how to prevent them from happening andimprove the factory. This initiative is called “near-miss activity.”
The important thing is to share as many of your near misses as you can. You need toreport even small mistakes. Participate in the activity with the desire to make the factory
and workplace safer than now by sharing a lot of near misses and making
improvements.
(3)

Participate in risk prediction training

Risk prediction training gives participants an idea of where and what dangers are in
the workplace or work, without having to experience near misses in person. It is training
to think about the potential hazards before you start work or when you learn a new task,
and then develop an ability to think about how to prevent industrial accidents causedby the hazards. It is also called KYT after the first letter of risk prediction training inJapanese (Kiken Yochi Training).

Source: The Ministry of Health, Labour and Welfare Safety and Health, “For Work
Safety and Health: To those working in the manufacturing industry”

People● Get caught in● Get caught inbetween● Get hit
● Fall over
● Fall down
● Get burned

Things● Get an electricshock● Hurt their back● Get poisoned bygas● Run out ofoxygen● Get damaged bya harmfulsubstance

Perhaps● Move● Spin● Fly● Fall● Fall out● Burn● Collapse● Unpile● Explode● Leak out

Perhaps- 54 ©OTAFFThere are various methods of risk prediction training, such as showing pictures andillustrations of equipment and machines during operation as well as the clothes andposture of workers and having each worker answer where and what hazards arepresent. The following examples are ideas to help workers become always cautious,
thinking that there might be a danger anywhere.
 Perhaps hot water gets into my boots and burn my foot.
 Perhaps a forklift comes out and hit me.
 Perhaps the loaded cargo unpiles and falls.
 Perhaps the floor in front of the freezer entrance is slippery because of a thinlayer of ice.
 Perhaps the kitchen floor is dirty with oil and slippery.
 Perhaps the fire on the gas stove cooking boiled food may have gone out withoutanyone noticing, and the gas may have spread inside.

5.

Cases of near misses and prevention of industrial accidents(1)“Falls” accident

Case 1[Situation]• When a worker was going to move, holding a tray
with both hands, he slipped on the wet floor andalmost fell over.
[Cause]• The water on the floor was not thoroughly wiped off.
[Countermeasures]• If the floor is wet, wipe off the water thoroughly.

- 55 ©OTAFF

Case 2
[Situation]• When a worker was walking down a parking lot
toward a truck, holding bread boxes with both
hands, he almost tripped over an empty box in thepassage.
[Cause]• There was an empty box in the passage.
• He could not see the floor because he wascarrying some bread boxes.
• The safety check of the passage was not sufficient.
[Countermeasures]•

Don’t leave things in the passage even if they areused for work.

• Check the safety of the passage before startingwork.
• When carrying more than one box, hold a limited
number of boxes so that they do not obstruct yourview.

- 56 ©OTAFF

(2)“Caught in or in between” accident

Case 1[Situation]• A machine on the packaging line stopped
because a product was jammed. When aworker opened the cover without pressing thestop button to remove the jammed product, themachine suddenly started to move, and his
hand almost got caught.
[Cause]• He did not confirm that the packaging line stopped completely by pressing the stop
button of the packaging line.
• There was no safety device to automatically stop the machine when the cover was
opened.
[Countermeasures]• Install a safety device that automatically stops the machine when the cover isopened.
• Press the stop button and confirm that the machine has stopped before starting work.
Case 2[Situation]• When a worker was cleaning a conveyor belt
without stopping it, a wiping cloth was caught,
and his hand almost got caught.
[Cause]• The conveyor belt was not stopped whencleaning.
[Countermeasures]• When cleaning, removing foreign objects,
inspecting, repairing, etc., press the stop buttonand confirm that the machine has stopped.

- 57 ©OTAFF

(3)“Cuts/Scratches” accident

Case 1[Situation]• When a worker was slicing bread while
pushing it with his hand on the work bench,
the slicer blade almost cut his finger.
[Cause]• Instead of using a pusher, he was pushingbread by hand to slice it.
[Countermeasures]• When using a slicer, use a pusher to push bread.
Case 2[Situation]• When a worker was cutting frozen fish with a knife, the knife he was holding slipped
and almost cut his other hand.
[Cause]• He was not wearing a protective glove (cut-resistant glove) on the other hand.
[Countermeasures]• Hold and cut according to working posture and frozen fish to be processed.
• Wear cut-resistant gloves.

(4)“Falling” accident

Case[Situation]• When a worker took products off the shelf with both
hands and was going to get off a stepladder, thestepladder moved, and he lost his balance andalmost fell off.

- 58 ©OTAFF

[Cause]• The safety lock of the stepladder was not on.
• There was no one to hold the stepladderso it would not fall over.
[Countermeasures]• Always use stepladders with safety
locks on. When getting on and off a
stepladder, leave one hand open andgrab the stepladder.
• For large products, two people work
together.

(5)“Burn” accident

Case[Situation]• When a worker was going to transfer an iron plate of
the oven to another worktable, he almost touched theiron plate with his bare hands without noticing that it
was hot.
[Cause]• Although the iron plate was hot right after taking it outof the oven, he was going to carry it with his barehands without checking the temperature of the ironplate.
[Countermeasures]• Wear protective gloves when carrying iron plates, pots, kettles, etc.
• Check the temperature before carrying, and if the temperature is high, tell the people
around you to be careful.
(6)“Lower back pain” accident

Case[Situation]• When a worker lifted a heavy kettle with both hands, hefelt a strong pain in his lower back.

- 59 ©OTAFF

[Cause]• He tried to lift a heavy object in an unstable position.
[Countermeasures]• When lifting a heavy object, bring yourbody close to the heavy object, bend yourknees, crouch down, hold the heavy object,and stand up slowly while straightening
your knees.
• When carrying heavy objects, use a trolley
if possible.

(7)“Heatstroke” accident

Case[Situation]• During the process of red bean processing, when a worker was putting beans into
a hopper and weighing them repeatedly, he became unsteady when moving andwas diagnosed with heatstroke.
[Cause]• He continued working in a place with high temperature and humidity without taking
a break.
• He was sweating a lot but did not drink water or consume salt.
[Countermeasures]• When working in places with high temperature and humidity, take frequent breaks
to drink water and consume salt.

- 60 ©OTAFF• Wear clothes that breath, absorb sweat, and dry easily.
(*) If you experience heatstroke-like symptoms in theworkplace, take the following actions:
1) Let the person in charge know.
2) Move to a cool place.
3) Take some rest.
4) Unbutton the work clothes and cool your body (especially
your neck, armpits, and groin).
5) Drink salty water or electrolyte drinks.
(8)“Crash” accident

Case[Situation]• When a worker was carrying empty boxes to thestorage area outside the workplace with a forklift,
he did not stop the forklift at the warehouse
entrance and almost hit someone from the side.
[Cause]• He did not stop the forklift at the warehouse
entrance.
[Countermeasures]• Forklift drivers must stop at the warehouse
entrance and check the safety by finger pointing
and calling.

- 61 ©OTAFFSupplementary Materials
Examples of safety signs used in the workplace
Main safety signs
1) Entry prohibited sign

2) No running sign3) Close door sign

4) Do not touch signs5) Pinch point signs

WATCH
YOUR
HANDS

6) Burn hazard signs

BURN
HAZARDBURN
HAZARD- 62 ©OTAFFWATCH YOUR
HANDS

7) Trip hazard signs
CautionSlipperySurface

WATCH
YOUR
STEP

DANGER!
RISK OFFALLING

8) Falling hazard signs9) Cutting hazard sign

FALL HAZARD!

KEEP HANDS CLEAR

10) Machine operation hazard signs

KEEP AWAY FROMMACHINERY
WHILE OPERATING
11) Electrical hazard sign12) Overhead hazard signs

WATCH YOUR HEAD

- 63 ©OTAFF

13) Eye protection signs14) Emergency exit signs15) Fire extinguisher signs

FIRE EXTINGUISHER- 64 ©OTAFF

Index(Note) This index covers Chapters 1 through 3 of this textbook.

A
Anisakisu

Anisakis................................................................ 14

Anisakisu shokuchuudoku

Anisakis food poisoning ....................................... 14

Arerugi-hanno

Allergic reaction ................................................. 8, 9

Arerugi-busshitsu

Allergic substance ...................................8, 9, 26, 32

ArerugenAllergen .................................................................. 8

Anzen kaba-

Safety cover ......................................................... 50

Anzen gutsu

Safety shoe .......................................................... 46

Anzen souchi

Safety device ............................................49, 50, 57

Anzen hyoshiki

Safety sign ........................................................... 62

Anzen hogogu

Safety protective equipment ........................3, 46, 51
I

IbutsuInshokur youhin seizougyou

Foreign object ............................. 7, 8, 18, 19, 32, 57
Manufacture of food and beverages....1, 2, 3 ,42, 53
U

Wherushu kin

Clostridium perfringens ............................. 11, 13, 33
EEisei kanri

Hygiene control...3, 5, 6, 15, 16, 18 ,26, 27, 32, 37, 38

Ekkususen ibutsu kenshutsuki X-ray foreign object detector .....................32, 36, 39
EpuronApron ............................................................. 26, 51
O

Oushoku budou kyuukin

Staphylococcus aureus ............................. 11, 12, 36

Osen sagyou kuikiContaminated work area ..........................16, ,17, 24- 65 ©OTAFFKa
Kaizen sochi

Remedial action ........................................38, 39, 40

KaitouThawing ......................................................... 31, 32

KaifuuOpening ............................................................... 31

Kaon

Heating........................................................... 31, 32

Kagakuteki kigai youin

Chemical hazard ............................................ 7, 8, 9

Kanetsu sakkin

Heat sterilization ............................................ 33, 39

Kanetsu chouri

Cooked.................................... 11, 13, 16, 26, 33, 38

Kaba-tsuki nagagutsu

Boot with cover .................................................... 46

Gahou

Spore .................................................. 11, 12, 13, 33

Gahou kin

Spore-forming bacteria......................................... 33

Kansen shou

Infection ............................................................... 45

Kanpirobakuta- zokukin

Campylobacter spp. ........................................ 11, 36

Kanri kijyun

Management standard ........................37, 38, 39, 40

Kanri kijyun karano itsudatsu Deviation from management standard ................. 39
Kigai youin

Ki
Hazard........ 6, 7, 8, 9, 10, 16, 26, 27, 33, 34, 37, 38, 39, 40

Kigai youin bunseki

Hazard analysis ............................................... 5, 37

Kiken yochi kunren

Risk prediction training ................................... 54, 55

Kisei chuu

Parasite .......................................................... 10, 14

KirokuRecord ..........................................27, 30, 38, 40, 54

Kinkyuu teishi botan

Emergency stop button .................................. 51, 52- 66 ©OTAFF

Kinzoku tanchi ki

Metal detector .....................................35, 36, 39, 40
Ku

Kusari tebukuro

Stainless-steel gloves .......................................... 46

Kubun eisei kanri

Zoning ............................................................ 16, 21Ke

Kenkou chekku

Health check ........................................................ 18

Genzairyou no hokan

Storage of ingredients .......................................... 29
Ko

Kousa osen

Cross-contamination .................................16, 17, 18

Koushitu ibutsu

Hard foreign object ............................7, 8, 15, 35, 36

Go esu5S................................................................5, 15, 44

Gomu tebukuro

Rubber gloves ...................................................... 46
Sa

SaikinBacteria ............................................... 10, 11, 12, 33

Sakiire sakidashi

First-in, first-out .............................................. 31, 36

Sagyou fuku

Work clothes . 3, 5, 15, 18, 19, 20, 21, 26, 27, 45, 61

Sagyou tejyun sho

Operating procedures .....................3, 26, 44, 47, 48

SakkinSterilize, Sterilization ............... 12, 13, 16, 33, 34, 39

Sarumonera zokukin

Salmonella spp. .............................................. 11, 36
Shi

Jiaensosan natoriumu

Sodium hypochlorite....................................... 13, 34

Shigyou mae tenken

Pre-commencement inspection ...................... 48, 49- 67 ©OTAFF

Shisa koshou

Finger pointing and calling ........................47, 48, 61

Shizen kaitou

Room temperature thawing .................................. 31

Shita shori

Prepare, Preparation ...................................7, 16, 31

Shitsuke

Self-discipline ................................................. 15, 45

Shuukanduke

Sustaining ...................................................... 15, 45

Jyuuten

Filling.............................................................. 34, 35

Jyuuyou kanri ten

Critical control point.........................5, 37, 38, 39, 40

Jyun seiketsu sagyou kuiki

Semi-clean work area .................................... 16, 17

Shiyou kigen

Use-by date .......................................................... 30

Shouhi kigen

Expiration date ....................................27, 30, 31, 35

Shoumi kigen

Best-before date .......................................30, 31, 35

Shokuchuudoku kin

Food poisoning bacteria ................ 10, 11, 12, 13, 33

Shokuchuudoku yobou no sangensoku
Three principles of food poisoning
prevention .................................................... 12, 14
Shokuhin eisei

Food hygiene ............................................3, 4, 5, 15
SuSuirei

Water cooling ....................................................... 34
Se

Seikei

Molding ................................................................ 32

Seiketsu

Clean/Standardizing.......................... 5, 12, 15, 16, 17, 19, 30, 32, 34, 45

Seiketsu sagyou kuiki

Clean work area ............................................. 16, 17

SeisouCleaning/Shining ...........................15, 17, 30, 45, 57

SeitonSetting-in-order .............................................. 15, 45- 68 ©OTAFF

Seibutsuteki kigai youin

Biological hazard .........................................7, 10, 33

Seiri

Sorting............................................................ 15, 45

Sereusu kin

Bacillus cereus .................................... 11, 12, 13, 33

SenjouWash, Washing ........................... 7, 9, 12, 13, 17, 32
So

SouzaiReady-made meal ................................................ 38

Souzai seizo gyou

Ready-made meal manufacturing ........................ 16

Zo-ningu

Zoning .................................................................. 16

Soranin

Solanine ........................................................... 8, 10
Ta

Tai sessou tebukuro

Cut-resistant glove ......................................... 46, 58

Tainetsu epuron

Heat-resistant apron............................................. 46
Chi

Chuushin ondo

Center temperature .......................13, 33, 34, 39, 40

Chouen biburio

Vibrio parahaemolyticus ........................................ 11

Choukan shukketsusei daichoukin
Enterohemorrhagic E. coli ..................................... 11
Chouri kigu

Cooking utensil ................................................ 9, 12
Te

TearaiHand washing, Wash hands............................................ 5, 12, 13, 14, 24, 25, 26

Tesuto pi-su

Test piece ............................................................. 35

Tebukuro

Gloves ...................................................5, 19, 26, 51

DengenPower ............................................................. 49, 50- 69 ©OTAFF

To
DokusoToxin................................................................ 11, 12

Tokutei genzairyou

Specified ingredients .............................................. 8

Tokutei genzairyou ni jjyunzuromono
Items equivalent to specified ingredients ............... 8
Toppingu

Topping ................................................................ 16

Dorippu

Purge ................................................................... 31
Ni

Niji saigai

Secondary accident.............................................. 51
Ne

Necchuu shouHeatstroke ...................................................... 44, 60
NoNorouirusu

Norovirus...................................................13, 14, 33

Norouirusu ga genin no shokuchuudoku wo Yobou surutameno yon gensoku
Four principles of food poisoning prevention caused
by norovirus ......................................................... 14Ha
Hainrihhi no housoku

Accident triangle .................................................. 53

Haza-doHazard ................................................................... 6

Haza-do bunseki

Hazard analysis ................................................... 37

Hasappu niyoru eisei kanri

Hygiene control by HACCP .......................... 5, 6, 37

Hasappu no nana gensoku

Seven principles of HACCP ................................. 37

Hasappu puran

HACCP Plan .......................................................... 5
Hi

Hikanetsu chouri

Uncooked ............................................................. 26

Hijyouteishi botan

Emergency stop button ........................................ 49

Hisutamin

Histamine ........................................................... 8, 9

Hisutamin chuudoku

Histamine poisoning ............................................... 9- 70 ©OTAFF

Biseibutsu

Microorganism ...... 10, 14, 17, 19, 21, 24, 32, 33, 34

Biseibutsu kensa

Microbiological examination ................................. 36

Hiyari・hatto

Near miss ..................................................53, 54, 55

Hiyari・hatto katsudou

Near-miss activity ........................................... 53, 54

Byougensei biseibutsu

Pathogenic microorganism ...10, 15, 16, 18, 26, 33, 34
Fu

Fuurei

Air cooling ............................................................ 34

Fu-ru puru-fu

Foolproof .............................................................. 50

Fye-ru se-fu

Fail-safe ............................................................... 50

Butsuriteki kigai youin

Physical hazard .................................................. 7, 8
He

Herumetto

Helmet.............................................................. 3, 46

BentouLunchbox ............................................................... 2
Ho

HousouPackaging .....................................16, 27, 34, 35, 57

Hokan ondo

Storage temperature ...................................... 29, 36

Hogo megane

Safety glasses ................................................ 46, 51

Botsurinusu kin

Clostridium botulinum...................................... 11, 33- 71 ©OTAFFMaMazeruMix ....................................................................... 17
Mi

Miton tebukuro

Mitten glove .......................................................... 46

Mimi sen

Earplug................................................................. 46
Me

Mekuseru tebukuro

Mexcel gloves ...................................................... 46
Mo

Moritsuke

Serving ......................................................16, 24, 26
Ya

Yakuzai

Chemical ................. 8, 13, 16, 18, 32, 34, 39, 44, 51

Yakuzai no kanri

Management of chemical ..................................... 18

Yakuzai niyoru sakkin

Chemical sterilization, Sterilized by chemicals....................................................................... 16, 39
Ri

Ryuusui

Running water ................................................ 31, 32

Ryuusui kaitou

Running water thawing, Thawing under running water....................................................................... 31, 32
Re

Reikyaku

Cooling ......................................................33, 34, 39

ReitouFreeze, Freezing, Frozen .......... 9, 14, 28, 31, 34, 58

ReitoukoFreezer......................................................30, 34, 55
Ro

Roudou anzen

Labor safety ................................................3, 15, 41

Roudou saigai

Industrial accident........ 3, 42, 43, 44, 45, 47, 48, 49, 51, 52, 53, 54, 55- 72 ©OTAFF

Notes• CopyrightThe copyright of Specified Skill Workers (i) Manufacture of Food and Beverages Skills
Proficiency Test Textbook for Learning (4th Edition) belongs to the Organization forTechnical Skill Assessment of Foreign Workers in Food Industry.
• Links
No permission or contact is needed to link to our website. However, it should be clearly
indicated that the link leads to the website of the Organization for Technical Skill
Assessment of Foreign Workers in Food Industry.
• Description of sources
If the contents of this textbook are used, the source should be provided. In addition,
when the contents of this textbook are edited or altered for use, that should be stated
together with the source mentioned above. Do not publish or use edited or alteredinformation as if it were created by us.
• Disclaimers
We assume no responsibility for any actions to be taken with the contents of thistextbook. This includes the use of information obtained by editing and altering thecontents of this textbook. The contents of this textbook may be changed or deleted
without prior notice.

- 73 ©OTAFF

[References]• “Ready-made Meal Manufacturing Work: Technical Intern Training Learning
Textbook (1st Edition)”
The Organization for Technical Skill Assessment of Foreign Workers in Food
Industry (November 2022)• “For Work Safety and Health: To those working in the manufacturing industry”
The Ministry of Health, Labour and Welfare and others (2016)• “Safety and Health Manuals for Technical Intern Trainees (Food Processing
Industry)”
Organization for Technical Intern Training (2021)• “Learning Tool to Produce Safe Food: Hygiene Control by HACCP”
Japan Food Industry Association (2018)• “Near-miss Incidents,” Industrial Accident Cases, Workplace Safety Website, theMinistry of Health, Labour and Welfare• “Hygiene Management Manual for Large-scale Food Preparation Facilities”
The Ministry of Health, Labour and Welfare (1997)- 74 ©OTAFF