Lesson 1Labeling and allergen control records: label samples, label approval forms, allergen matrix, segregation proceduresThis details how auditors look at labeling and allergen control records, including label okays, allergen tables, change checks, and separation looks, to confirm true labeling and stop allergen mixing in Zambian salad production.
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 covers process control records like cleaner levels, line checks, foreign body control, and packaging strength. Auditors check that monitoring is on time, noted, and starts good fixes when limits fail in Zambia.
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 logsWe explain checking maintenance and calibration records. Auditors confirm planned upkeep, fix repairs, and calibration of key tools like metal detectors, x-ray, thermometers, and scales in Zambian food plants.
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 addresses cleaning proof and microbe testing records. Auditors look at site monitoring, product tests, methods, and trend checks to confirm pathogen and cleaning controls are working and based on proof in Zambia.
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 focuses on complaint and recall papers. Auditors check complaint lists, probes, fix actions, and practice recall tests to judge quick response, root-cause quality, and recall readiness and strength in Zambian operations.
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 traceabilityWe explain how auditors check supplier okay files, including risk-based okay, specs, audits, COAs, and incoming check records, ensuring match with product risk, tracking, and steady supplier work in Zambia.
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 covers checking basic program records, including good practices, cleaning and sanitation, and pest control. Auditors confirm plans, duties, times, and check proof to ensure strong base controls in Zambian sites.
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 covers checking receiving and release records. Auditors look at incoming inspections, temp logs, lab results, and release choices to ensure only rule-following raw materials and products enter and leave in Zambia.
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 acknowledgementsWe explain how auditors check training and worker cleaning records, including training tables, attendance, skill checks, health screens, and good practice okays, to confirm staff are fit and know food safety tasks in Zambia.
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 details how auditors check HACCP and food safety plans, looking at hazard analysis, key point picks, critical limits, monitoring, fix actions, and check records to confirm the system is up-to-date, full, and in use in Zambian plants.
Checking hazard analysis completenessVerifying CCP identification and rationaleAssessing critical limits and validationReviewing monitoring forms and recordsEvaluating corrective and preventive actionsConfirming plan review and revalidation
