6 replies to this topic

[Jewl578]

I am 100% new to the QAC position here at a small manufacturing plant. I am told I need to come up with an internal auditing program and have absolutely no idea where to start. ANY and ALL help would be appreciated! I am GREEN, GREEN, GREEN! We're talking zero management experience. I need to write the policy, the criteria, etc. If there are any samples out there that I can tailor to our plant, that would be great. Thank you! Our BRC Audit is the middle of Oct. I came on board to this position only 2 months ago if that will help you understand how much in the dark I am. We are such a small plant that funds are limited for training on my part. I was willing to give this job my best and that I am determined to do!

[Foodworker]

You haven't made life easy for yourself have you!!!

I am guessing that this is your company's first BRC audit otherwise you should already have an internal audit procedure and schedule in your existing documents.

Internal Audits is one of the Fundamental requirements of the Standard, which raises it to a higher level of expectation during the audit.

The audits must be carried out by independent, appropriately trained auditors. From your description of yourself it sounds as though you have not received any internal auditor training. Given the timeframe, it is going to be very difficult to find an appropriate course and carry out audits on enough of the operation to get through the BRC audit.

In your position I would buy in a full BRC mock internal audit from an external trained auditor with knowledge of the BRC and your sector. This should be about 2 days work and will count as an internal audit.

You will still need to put together a schedule which can demonstrate that the frequency of internal audits is risk based.

Without seeing your Manual and Procedures I can't be very precise but I am attaching a generic Internal Audit procedure and schedule which, whilst not perfect, covers most of the requirements.

[Foodworker]

I'll try attaching them this time!

Ignore the reference to office based staff in the procedure this was just for a very small company where it was very difficult to demonstrate independence

Attached Files

•  Int Audit Schedule.doc   121.5KB   681 downloads
•  QP02 Procedure for Internal Audits.doc   31.5KB   677 downloads

Edited by Foodworker, 08 September 2011 - 05:37 PM.

[Charles.C]

Dear Foodworker,

Nice documents.

It all rather depends on the process of course, growing potatoes or making pizzas.

From MEX, I imagine the audit form you mention is something like a checklist aligned to the standard with an included corrective action section.

I like the term "Factory standards", so short but covers so much.

So much comes down to money, as usual. Even without the auditor factor, I second yr suggestion regarding a dummy run, especially if it can also be done by a likely future overseer. I got a gratuitous aperitif of a preliminary desk-top appraisal when I did it.

I also believe from conversations with other applicants that the full ferocity of the auditory sword is often very slightly sheathed for Audit No.1. Don't kill the Golden egg etc.

Best Rgds / Charles.C

[aps]

Nice schedule, do you have a risk assessment to determine frequency?

[Foodworker]

No, I don't have a documented risk assessment to determine frequency.

I have in the past applied a likelihood and severity scoring martrix to this, but it was far too complex and I only ended up with something similar to this schedule so I stopped and just used the common sense approach.

ie topics such as contamination control, HACCP, allergens are bound to carry more direct risk to the product or chances of problems being found than the organisational structure or Policy.

As long as the schedule can demonstrate an element of frequency varying according to risk, that should be sufficient to the auditor.

The phrase 'Factory Standards' is a bit of a catch-all intended to cover the floor/walls/ceilings and anything which doesn't fit in one of the other bits.

[Jewl578]

No, it isn't easy, I'll be the first to admit somedays I feel way in over my head.
Thanks for the documents.
We did have a BRC Audit last Oct. but there was no QAC onboard at the time. I just came along 2 months ago. Had internal auditor training last month, along with my 2 QC Techs. They are even newer to this than I am.
I do have the support of the company management which helps to an extent.
I do know the basics of HACCP, Food Safety, etc.
We have a great USDA inspector who is more than willing to help me understand why things are done the way they are.
Made some progress here, and feel I can at least start the internal audit now.
Thanks for the help, I'm sure I'll be back with more questions.

You haven't made life easy for yourself have you!!!

I am guessing that this is your company's first BRC audit otherwise you should already have an internal audit procedure and schedule in your existing documents.

Internal Audits is one of the Fundamental requirements of the Standard, which raises it to a higher level of expectation during the audit.

The audits must be carried out by independent, appropriately trained auditors. From your description of yourself it sounds as though you have not received any internal auditor training. Given the timeframe, it is going to be very difficult to find an appropriate course and carry out audits on enough of the operation to get through the BRC audit.

In your position I would buy in a full BRC mock internal audit from an external trained auditor with knowledge of the BRC and your sector. This should be about 2 days work and will count as an internal audit.

You will still need to put together a schedule which can demonstrate that the frequency of internal audits is risk based.

Without seeing your Manual and Procedures I can't be very precise but I am attaching a generic Internal Audit procedure and schedule which, whilst not perfect, covers most of the requirements.