Lesson 1Labeling and allergen control records: label samples, label approval forms, allergen matrix, segregation proceduresThis lesson details how auditors look at labeling and allergen control records, including approvals, matrices, change management, and segregation checks, to ensure correct labeling and no allergen cross-contact.
Reviewing label approval workflowsChecking artwork and text versionsAssessing allergen matrix accuracyReviewing change control recordsEvaluating allergen segregation checksChecking rework and label reconciliationLesson 2Process control records: wash water monitoring (chlorine/other sanitizer), cutting line checks, metal detector/x-ray logs, packaging sealsThis lesson covers process control records like sanitizer levels, line checks, foreign body control, and packaging strength. Auditors confirm monitoring is prompt, recorded, and leads to good corrective steps when limits are missed.
Reviewing wash water test recordsChecking cutting and trimming line checksAssessing metal detector and x-ray logsReviewing packaging seal integrity testsEvaluating trend charts and control limitsChecking responses to out-of-spec resultsLesson 3Maintenance and calibration records: calibration of metal detectors/x-ray, thermometers, scales, and preventive maintenance logsThis lesson explains checking maintenance and calibration records. Auditors verify preventive upkeep, repair fixes, and calibration of key devices like metal detectors, x-ray units, thermometers, and scales.
Reviewing preventive maintenance schedulesChecking completed maintenance work ordersAssessing calibration certificates and datesVerifying critical control device checksReviewing out-of-tolerance investigationsLinking equipment issues to product impactLesson 4Sanitation validation and microbiological testing: environmental monitoring (Listeria spp./L. monocytogenes), finished product testing, trend analysisThis lesson addresses sanitation validation and microbiological testing records. Auditors check environmental monitoring, product testing, methods, and trend reviews to confirm pathogen and hygiene controls are effective and based on evidence.
Reviewing validation study reportsAssessing environmental monitoring plansEvaluating Listeria sampling and resultsReviewing finished product test recordsChecking lab methods and accreditationAssessing microbiological trend analysisLesson 5Complaint and recall records: complaint log, root-cause investigations, corrective actions, mock recall outcomesThis lesson focuses on complaint and recall documentation. Auditors review logs, investigations, corrective steps, and mock recall tests to gauge responsiveness, root-cause quality, and recall preparedness and success.
Assessing complaint intake and loggingEvaluating root-cause investigationsReviewing corrective and preventive actionsChecking communication with customersAssessing recall and withdrawal proceduresReviewing mock recall test resultsLesson 6Supplier approval files: supplier specifications, audits, COAs, incoming inspection records — alignment with risk and traceabilityThis lesson explains how auditors assess supplier approval files, including risk-based approval, specs, audits, COAs, and incoming inspection records, ensuring they match product risk, traceability, and supplier performance.
Reviewing supplier risk assessmentsChecking approved supplier listsAssessing supplier specifications and COAsReviewing supplier audit and visit reportsEvaluating incoming inspection recordsVerifying traceability to supplier lotsLesson 7Prerequisite program records: GMPs, cleaning & sanitation schedules and verification, pest control logs — frequency, responsible persons, and verificationThis lesson covers checking prerequisite program records, including GMPs, cleaning and sanitation, and pest control. Auditors verify schedules, duties, frequencies, and proof to ensure solid basic controls.
Reviewing GMP inspection checklistsEvaluating cleaning and sanitation schedulesChecking sanitation verification resultsReviewing pest control service reportsAssessing pest sighting and trend logsVerifying responsibilities and sign-offsLesson 8Receiving and release records: inbound checks, temperature logs, lab test results for raw produce and ingredientsThis lesson covers reviewing receiving and release records. Auditors check inbound inspections, temperature logs, lab results, and release choices to ensure only compliant raw materials and products enter and exit the system.
Checking inbound receiving checklistsReviewing temperature monitoring logsAssessing raw material test resultsEvaluating release authorization recordsVerifying hold and release controlsChecking rejection and nonconformance logsLesson 9Training and personnel hygiene records: training matrices, competency assessments, health screening and GMP acknowledgementsThis lesson explains how auditors review training and personnel hygiene records, including matrices, attendance, competency checks, health screening, and GMP acknowledgements, to confirm staff are skilled and aware of food safety roles.
Reviewing training matrices and plansChecking training attendance recordsAssessing competency evaluationsReviewing hygiene and GMP trainingChecking medical and health declarationsVerifying refresher training frequencyLesson 10HACCP/food safety management system documentation: hazard analysis, CCP identification, limits, monitoring and corrective actions — completeness and currencyThis lesson details how auditors review HACCP and food safety plans, checking hazard analysis, CCP choice, critical limits, monitoring, corrective actions, and verification records to ensure the system is up-to-date, full, and active.
Checking hazard analysis completenessVerifying CCP identification and rationaleAssessing critical limits and validationReviewing monitoring forms and recordsEvaluating corrective and preventive actionsConfirming plan review and revalidation
