Lead Hands in the food processing industry work in production plants that conduct primary processing of agricultural commodities, or refine or manufacture a range of food and beverage items or nutraceuticals. Lead Hands play an intermediate role between production workers and shift supervisors.

• working with others.
• problem-solving.
• oral communication.
• document use.

The typical text reading tasks of Lead Hands are at Complexity Levels 1 and 2. Their most complex text reading tasks are at Complexity Level 3.

Lead Hands:

• read brief notes about work or equipment procedures or problems, written by a supervisor, co-worker or member of the maintenance or sanitation department. (1)
• may read reminder notes they have made for themselves. For example, read a note to remember the steps in a process. (1)
• read internal memos regarding new processes, products and equipment. (occasionally) (2)
• may read marketing pamphlets, information sheets or detailed labels which describe items that the plant produces. (occasionally) (2)
• read company procedures in order to clarify information for other workers (2)
• read training manuals for refresher or upgrading courses on topics such as Workplace Hazardous Materials Information System (WHMIS), forklift operation or first aid. (3)
• may read test instructions and multiple-choice questions as part of courses such as those for the Hazard Analysis Critical Control Point (HACCP) system or for industrial first-aid. (3)
• seek specific information in operating manuals for production and packaging machinery in order to make minor adjustments or repairs. (occasionally) (3)

The typical document reading tasks of Lead Hands are at Complexity Levels 1 and 2. Their most complex document reading tasks are at Complexity Level 2.

Lead Hands:

• read a daily production schedule to know which products to make during the shift and to determine if machines must be changed over for a new product run. (1)
• read product labels in order to check that the expiry date and product name/code are correct (frequently) (1)
• may check worker time-sheets to verify the total hours worked. (1)
• read product formulation lists to know the quantities of specific ingredients to combine in a product batch. (1)
• may select a series of menu items on a computer screen in order to adjust or begin some aspect of production, for example, to cause a machine to dump an ingredient from a storage bin into a mixer. (1)
• read a table to make adjustments to machine controls; for example, for a specific food moisture content, they find in the table the correct frying/cooking temperature at which to set a fryer or oven. (2)
• may refer to a specific diagram in an equipment manual or on a computer screen to diagnose or solve minor problems. (2)

Lead Hands:

• may complete a daily production summary form, listing or checking off the type and amount of product, and writing in counts or weights. They may occasionally add a brief note to explain why production quotas were exceeded or were not met.
• may complete tracking forms during a shift to document total quantities of products produced at specific time intervals.
• may complete an inventory form on a regular basis (daily, weekly, monthly or annually) by checking off items on a list and writing the quantities in stock.
• may draw rough sketches in a personal notebook, e.g. to remember the order in which to re-assemble machine parts.
• read pressure and temperature gauges on tanks

Lead Hands:

• read signs, labels or lists.
• complete forms by marking check boxes, recording numerical information or entering words, phrases, sentences or texts of a paragraph or more.
• read completed forms containing check boxes, numerical entries, phrases, addresses, sentences or texts of less than a paragraph.
• read tables, schedules or other table-like text.
• enter information on tables, schedules or other table-like text.
• obtain specific information from graphs or charts.
• may draw simple assembly drawings.
• may read schematic drawings.
• obtain information from sketches, pictures or icons.

The typical writing tasks of Lead Hands are at Complexity Level 1. Their most complex writing tasks are at Complexity Level 2.

Lead Hands:

• write simple notes, memos or work orders to the next shift or the maintenance crew to inform them of an equipment problem or to request follow-up action. (1)
• may write notes to themselves when learning new job tasks, for example, to remember new process steps. (1)
• may occasionally write brief notes on a daily production summary form to explain why production quotas were exceeded or were not met. (1)
• may write short answers to questions as part of a formal training evaluation or re-qualification, e.g. HACCP, WHMIS, first aid. (2)
• write reports to supervisors describing production problems and events that lead to them. (2)

The numeracy tasks of Lead Hands involve:

• measurement and calculation math at Complexity Levels 1 and 2.

• numerical estimation at Complexity Level 1.

• count the total number of items produced in a specific time period, e.g., during an 8-hour shift. (measurement and calculation) (1)
• weigh or take the temperature of food products in either metric or imperial units, using either a gauge or a digital readout display. (measurement and calculation) (1)
• calculate the number of containers needed to hold a specific number of product units, taking into consideration how may units each container holds. (measurement and calculation) (1)
• calculate the total number of production batches/cycles and time required to fill a product order, knowing the number of units produced per batch/cycle and the average run-time per batch/cycle. (measurement and calculation) (2)
• may convert total production weight from one unit to another, for example, converting 4 oz. to _ lb. Or 40, 4 oz. units to 10 lbs.. (measurement and calculation ) (2)
• may calculate the ingredient weights or volumes for a partial-batch "recipe" (for example, a _-batch). (measurement and calculation) (2)
• estimate the total time required to fill each production order in a shift, considering the production rate of various machines and possible down-time for machinery malfunction or production bottle-necks. (numerical estimation) (1)

a. Mathematical Foundations Used

b. How Calculations Are Performed

• in their head.
• using a pen and paper.
• using a calculator.

c. Measurement Instruments Used

• time - using a watch or clock.
• weight or mass - using a gauge or a digital scale.
• liquid volume - using a graduated cylinder, calibrated vat or a pipe-valve volume monitor.
• temperature - using a digital thermometer.
• pressure - using a pressure gauge.

• the metric measurement system.
• the imperial measurement system.

The typical oral communication tasks of Lead Hands are at Complexity Levels 1 and 2. Their most complex oral communication tasks are at Complexity Levels 2 and 3.

Lead Hands:

• train new workers by showing and describing standard tasks and equipment operation. This may involve hand gestures and other signals if workers have limited English comprehension. (1)
• learn about new production plans or procedures by listening to their supervisors. Listen in meetings or training sessions to learn how to operate new equipment. (1)
• frequently inform production workers and other Lead Hands of production line changes or of new procedures or products. (1)
• give performance feedback to production workers to motivate or improve adherence to operating procedures or quality standards. (2)
• frequently exchange information about production or equipment problems with production/shift supervisors, by radio or in person. (2)
• answer questions that quality-control, safety or management personnel ask about work procedures or product characteristics. (2)
• may telephone shippers/receivers or suppliers to find out about availability of product ingredients or packaging materials, or to order more. (2)
• discuss production priorities with other Lead Hands and the supervisor either on an ad hoc basis or in meetings, to change or adjust worker assignment or the flow of materials, to avoid bottlenecks and to improve production efficiency. (3)

Lead Hands communicate:

• in person.
• using the telephone.
• using a two-way radio or other such means.
• using specialized communication signals. They may use hand signals to signal safety concerns or movement of materials. They may also use hand signals to demonstrate job tasks when training workers who do not speak English well.

Lead Hands in most production plants are required to wear hearing protection because of high noise levels; oral communication can be difficult. Large machinery and plant layout can also limit the use and effectiveness of hand signalling. Therefore, frequent radio communication is often used.

In many food processing plants there can be number of workers with limited English skills. In this case, Lead Hands may be required to train or give feedback to workers using hand signals to demonstrate job tasks, or they may have to find someone who can translate for them. Sometimes Lead Hands for a work group with a common first language other than English also speak that language and use it for on-the-job communication.

1. Problem Solving

The typical problem solving tasks of Lead Hands are at Complexity Levels 1 to 3. Their most complex problem solving tasks are at Complexity Level 3.

Lead Hands:

• may find that a machine is not producing the product with the required speed or quality. They adjust the equipment to solve minor problems, for example, portion-weight or vacuum-seal wrapping. (1)
• may be told by their supervisor that production priorities have unexpectedly changed during a shift, either due to a revised customer order or due to machinery malfunction. They delegate new tasks to production workers or move them to a different machine in order to optimize production or to change over to the new product process. (2)
• may observe that a production worker is not following standard operating procedures. They discuss and demonstrate the correct task performance with the worker, and continue to monitor their work performance. (2)
• may deal with equipment malfunctions or machine failures. They attempt the repairs themselves, but in some cases have to call maintenance personnel for assistance. (3)

The typical decision making tasks of Lead Hands are at Complexity Level 1 and 2. Their most complex decision making tasks are at Complexity Level 2.

• decide when to inform the production/shift supervisor or maintenance staff of an equipment problem rather than attempting to adjust or repair it him/herself. (1)
• decide when to inform the production/shift supervisor of continued unacceptable performance by a production worker. (1)
• decide when to shut down machines which are not operating properly (2)
• decide whether to reject a whole batch of product when a foreign object is found in one small portion of a mix. (2)

Lead Hands plan and organize their job tasks at Complexity Level 2.

Lead Hands are given daily production schedules and instructions from the shift/production supervisor. Their main task is to ensure that production workers are performing their tasks efficiently and safely, following standard operating procedures. Usually more than one product is being produced simultaneously. Therefore, a challenge for Lead Hands is to plan ahead by one or more hours, so that the timing of production stages ensures an efficient flow of materials through the whole production system. Production goals may be interrupted on a daily basis by unexpected customer orders, equipment malfunction, worker absenteeism or an inadequate supply of input or packaging materials. Lead Hands must communicate constantly with each other, with the shift/production supervisor, with maintenance staff, and sometimes with management personnel to adjust production plans and co-ordinate work priorities within the plant.

Examples

Lead Hands:

• remember passcodes and the entry-code sequence for computer log-on and keypad data entry.
• remember product specifications that may vary by customer order.
• remember product codes to check that packages are labelled correctly.
• may remember the disassembly/reassembly order for equipment when making minor repairs or demonstrating a cleaning process.

5. Finding Information

Lead Hands perform tasks that involve finding information at Complexity Levels 1 and 2.

Lead Hands:

• may telephone or radio other departments about availability of raw materials or supplies. (1)
• may telephone or use the radio to contact maintenance personnel to ask about equipment operation or troubleshooting. (2)
• may refer to equipment manual diagrams or instructions to find out how to make an adjustment or minor repair. (2)
• ask the shift/production supervisor about new priorities when changes to the daily production schedule occur. (2)

Lead Hands are part of a team made up of labourers, production workers, production supervisors, managers and quality-control, cleaning, maintenance and shipping/receiving personnel. Some workplaces emphasize a formal "team" model of performance, while in others it is implied rather than formalized. While many Lead Hands perform production tasks as machine operators, most are also responsible for frequent on-the-job training and performance feedback to production workers. Often Lead Hands attend weekly or monthly safety meetings. On a daily basis, they communicate with their immediate production supervisors, other Lead Hands and quality assurance/HACCP personnel about work priorities.

Lead Hands:

• participate in formal discussions about work processes or product improvement
• have opportunities to make suggestions on improving work processes.
• monitor the work performance of others.
• inform other workers or demonstrate to them how tasks are performed.
• orient new employees.
• assign routine tasks to other workers.
• may assign new or unusual tasks to other workers.

The computer use tasks of Lead Hands are at Complexity Levels 1 and 2.

• may use word processing. For example, they write short memos to the Maintenance Department to request equipment servicing. (1)
• may use a spreadsheet. For example, entering daily production totals onto a summary form. (1)
• may use communications software. For example, they read email messages. (1)
• may use computer-controlled equipment such as programmable logic control (PLC) systems. For example, they may enter or select a product code with a mouse-click, keyboard/keypad entry or touch-screen selection in order to designate the fill and wrapping criteria for a product moving through a packaging machine. (1)
• may use a database. For example, they make requests or read follow-up entries in a Maintenance Request log. (2)

Fairly constant upgrading or replacement of equipment in food processing/production plants means that Lead Hands are continuously involved in hands-on learning from the supervisor, equipment manufacturer or maintenance staff. Often electro-mechanical equipment is being replaced by electronically-controlled equipment. With increased computerization, Lead Hands must memorize new data entry codes (such as product codes) and keypad or screen input steps. Occasionally, Lead Hands must read manuals, updates or circulars on equipment upgrades or operational modifications. When new products are introduced, Lead Hands must learn about their specifications, formulation and about any special customer requirements. Lead Hands may take upgrading training outside of scheduled work time (for example, WHMIS, first aid or forklift refreshers). In workplace safety or quality-assurance meetings, Lead Hands are expected to learn about organizational standards of practice from oral and video presentations.

• as part of regular work activity.
• from co-workers.
• through training offered in the workplace.
• through reading or other forms of self-study:
  - at work.
  - using materials available through work.
• through off-site training:
  - during working or non-working hours at no cost to the worker.

In addition to collecting information for this Essential Skills Profile, our interviews with job incumbents also asked about the following topics.

The Lead Hands interviewed mentioned these physical aspects of their jobs:

Body Position

Lead Hands usually stand through the whole shift. They frequently walk between different areas or floor levels of the plant.

Limb Co-ordination

Lead Hands must use fine and gross motor skills when operating production equipment. They must also avoid moving equipment, to prevent injury to themselves and others.

Strength

Strength demands for Lead Hands are moderate and decreasing as equipment takes over carrying, lifting and dumping tasks. However, many Lead Hands still physically move, lift or push heavy materials on a daily basis.

Sensory

Lead Hands use their senses to detect if there are production or safety problems in the plant. For example, a burning smell or an unusual pitch or timing of sound can alert them to equipment malfunction.

The Lead Hands interviewed felt that Lead Hands should be patient and able to adjust to change. They should like working with, supervising, and teaching other people. They should be willing to listen to input from workers and instructions from supervisors. They should be willing to work on shifts, and sometimes to work long hours or long work-weeks of more than five days. They should be able to prioritize simultaneous requests or production demands, and to plan ahead. They should be mechanically inclined and should believe it is important to perform tasks correctly.

In food processing and production, mechanical systems are rapidly being replaced by electronic systems. Lead Hands will need greater knowledge and familiarity with computers, electronics, and digital process controls. A greater diversity of products and processes will also require continuous learning. There is also a trend to move more of the supervisory and decision-making responsibility down to the level of Lead Hands as organizational management structures are flattened, and as the pace of plant production continues to increase.

Copyright is held by the Alberta Food Processors Association.

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