Lesson 1Labelling and allergen control records: label samples, label approval forms, allergen matrix, segregation proceduresThis part details how auditors check labelling and allergen control records, including label approvals, allergen matrices, change control, and segregation checks, to confirm accurate labelling and stop 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 sanitiser), cutting line checks, metal detector/x-ray logs, packaging sealsThis part covers process control records like sanitiser levels, line checks, foreign body control, and packaging strength. Auditors confirm monitoring is timely, documented, and starts effective fixes when limits fail.
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 part explains checking maintenance and calibration records. Auditors confirm preventive upkeep, breakdown 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 part handles sanitation validation and micro testing records. Auditors check environment monitoring, product testing, methods, and trend analysis to confirm controls for pathogens and hygiene are effective and proof-based.
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 part focuses on complaint and recall docs. Auditors check complaint logs, investigations, fixes, and mock recall tests to judge responsiveness, root-cause quality, and recall readiness and strength.
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 part explains how auditors check supplier approval files, including risk-based approval, specs, audits, COAs, and incoming inspection records, ensuring match with product risk, traceability, and ongoing 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 part covers checking prerequisite program records, including GMPs, cleaning and sanitation, and pest control. Auditors confirm schedules, duties, frequencies, and verification proof to ensure strong base 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 part covers checking receiving and release records. Auditors check inbound inspections, temperature logs, lab results, and release decisions to ensure only compliant raw materials and products enter and leave the food safety 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 part explains how auditors check training and personnel hygiene records, including training matrices, attendance, competency checks, health screening, and GMP acknowledgements, to confirm staff are qualified and know food safety duties.
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 part details how auditors check HACCP and food safety plans, looking at hazard analysis, CCP selection, critical limits, monitoring, fixes, and verification records to confirm the system is up-to-date, full, and in use.
Checking hazard analysis completenessVerifying CCP identification and rationaleAssessing critical limits and validationReviewing monitoring forms and recordsEvaluating corrective and preventive actionsConfirming plan review and revalidation
