The Last 10 Feet: Where Food Safety Really Breaks Down

Food production worker reviewing safety checklist in bakery facility.

What’s Really Causing Food Safety Incidents?

Food safety is a top priority for every food manufacturing leader. You’ve invested in detailed SOPs, trained your teams, passed your audits, and probably implemented some form of ERP, CMMS, or digital checklist.

So why do costly food safety issues still happen?

The reality is, many failures occur not in the plan — but in the execution. In those final moments on the plant floor when something is forgotten, rushed, skipped, or misunderstood. We call this vulnerable zone the “last 10 feet” — and it’s where even great programs can quietly fall apart.

What Is the “Last 10 Feet” Problem?

The “last 10 feet” refers to the space between what’s supposed to happen and what actually happens — especially during busy shifts, staff transitions, or production pressure.

Here’s how it can show up:

• A sanitation step is missed but the log is still signed off.

• A team member rushes through an allergen changeover.

• A temperature check is skipped — because someone thought someone else did it.

These aren’t system failures. They’re execution gaps. And they happen more often than most teams want to admit.

💡 What makes this more dangerous? These breakdowns often leave no trace until a product issue, customer complaint, or inspection exposes the gap.

What the Data Says About Human Error in Food Manufacturing

It’s not just anecdotal — the data backs up the importance of real-time execution.

• According to The Canadian Food Inspection Agency's (CFIA), in 2023/24 there was a total of 248 recalls or a recall every 1.5 days.

• According to the FDA HACCP Manual, the top causes of foodborne illness outbreaks include employee-related mistakes like improper food temperatures, use of contaminated equipment, and poor hygiene — all execution risks that can occur during daily operations.

• According to Food Safety Magazine, recalls range from $9 million to more than $100 million, and are primarily attributed to product disposal costs, business interruption, and customer reimbursement. Most of these food safety problems could be controlled with human effort. 

🧠 Translation? You can have a great process — but if it’s not followed consistently, it puts everything at risk.

Why Audits and Training Still Leave Gaps

Audits are critical. So is training. But neither catches real-time lapses.

Here’s why:

• Audits are planned, periodic, and designed to show compliance — not day-to-day reality.

• Training is essential, but doesn’t guarantee follow-through when things get busy, new hires come in, or experienced staff leave.

It’s like this:

“You wouldn’t rely on a fire drill to put out a real fire. So why rely only on training or audits to catch real-time safety failures?”

These tools are necessary — but not enough. What’s missing is proof that SOPs are followed when no one’s watching.

What Happens When You Close the Last 10 Feet?

Let’s look at a hypothetical example that mirrors what many food manufacturers experience:

Imagine a mid-sized bakery that’s been struggling with repeat allergen control issues — despite having well-documented SOPs and regular training. Logs are being filled out, but issues still slip through during shift changes or when teams are short-staffed.

Now imagine this bakery introduces a real-time task verification system like Command Center. Within a few weeks:

• Missed sanitation steps drop dramatically — by as much as 95%

• Allergen control becomes far more reliable, with fewer “near misses” or corrective actions

• Supervisors receive instant alerts when steps are skipped, rather than finding out after the fact

• Shift handoffs improve because the system clearly shows what was done — and what wasn’t

The SOPs didn’t change. The people didn’t change. What changed was how the work was tracked and verified in real time.

That’s the power of closing the last 10 feet.

How Command Center Bridges the Gap

Command Center is designed to make sure what should happen actually does happen — especially during that last 10 feet.

Here’s how:

• Digital SOP guidance: Workers are prompted through each required task, one step at a time.

• Location & time-verified smart tags: Tasks can’t be marked complete unless done at the right location and time.

• Instant alerts for missed or delayed steps: Supervisors are notified in real time if something is skipped or overdue.

• Audit-ready data: Every action is logged automatically, creating full transparency without extra admin work.

📌 Unlike ERP or CMMS tools, Command Center focuses on human task execution — not just scheduling or planning. It’s a safety net for the real world.

Final Thought: It’s Time to Take Execution Seriously

Most food manufacturers have strong programs on paper. But the true measure of a safety system is what happens in motion, not what’s written in binders or checklists.

The “last 10 feet” isn’t a small detail — it’s where:

• Recalls start

• Brand trust is broken

• The cost of one missed step becomes millions

👉 If you’re ready to stop relying on hope and highlighters, maybe it’s time to look at real-time execution differently.

Your Turn: What’s Your Biggest Blind Spot?

We’d love to hear from you.

“Where do you see execution falling through the cracks most often? During shift changes? With new hires? On your busiest lines?”

Drop us a message or explore how Command Center helps food manufacturers turn SOPs into proof.

Rebecca Wormleighton

Co-founder, Zendelity

rebecca.wormleighton@zendelity.com