EMP Programme Builder
Build the environmental monitoring risk assessment for your plant or for a case site, sitting by sitting, in the ASC RA19 structure. Everything is saved on this device as you go. The review gate in step 9 exports the workbook and submits it for marking.
Step 1: The risk register lines
One line per zone, site and organism (lesson 3.4). Zone with the two question rule (lesson 3.1). Hazard is the organism on the surface; source is what causes it; the risk owner is a role. Tick FCS for a food contact surface and Drain for a drain. The organism justification comes from the product and the process, not a textbook.
| ID | Site / surface | Area | Zone | FCS | Drain | Hazard (organism on the surface) | Caused by / source | Risk owner (role) | Organism of concern and justification | Notes from the walk |
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Areas and sanitisers
Every line belongs to an area; every area has a sanitiser. The broth is matched to it in step 4.
| Area | Sanitiser in use |
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Step 2: Score every line, inherent and residual
Probability 1 to 5: rare; once in one to five years; a few times a year; about monthly; weekly or every batch. Severity 1 to 5: no food safety impact; minor; potential food safety issue; serious food safety issue; critical or systemic failure. Score before controls, list the controls that exist today and are verified, then score again. Controls reduce probability, not severity (lesson 3.4). Rating = probability x severity: 20 to 25 Critical daily, 10 to 16 High weekly, 5 to 9 Medium monthly, 3 to 4 Low-Med quarterly, 1 to 2 Low biannual.
| ID | Site | Zone | Inh P | Inh S | Inherent | Existing controls | Control owner (role) | Res P | Res S | Residual | Band | Frequency | Check |
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Step 3: Schedule matrix
Rotation
MorningAfternoonNight
MonTueWedThuFriSat
Four week matrix (weekly lines every week; monthly lines spread over the cycle; quarterly and biannual lines in week 4 of their month)
Step 4: Targets, methods and the neutraliser
| Zone | Routine target | Method | When |
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Cleaning verification programme (separate line, lesson 4.4)
Neutralising broth by area
| Area | Sanitiser | Broth on the sponge | Check |
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Laboratory
ISO 11290-1 Listeria detectionISO 11290-2 Listeria enumerationISO 6579-1 SalmonellaISO 21528-2 EnterobacteriaceaeISO 4833-1 aerobic plate countValidated rapid Listeria screen
Step 5: Action levels and response
Product hold and release
Product not detected for Listeria monocytogenes in 25 gThree consecutive negative production days on the surface
Step 6: The positive drill
The first hour
Star burst sites (at least 15, every direction)
Pick from the register or add new sites the register did not have. Tag each with its direction from the positive.
| Site | Direction | Day 1 | Day 2 | Keep for day 3 |
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Step 7: Root cause and CAPA
Five whys
Fishbone (one line per branch, leave blank if nothing)
Corrective actions (remove the cause)
| Action | Owner (name) | Date |
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Preventive actions (the same cause elsewhere)
| Action | Owner (name) | Date |
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Step 8: Action tracker and the note to management
Every line whose residual rating is Medium or higher carries a real action: what will be done, not what already exists. Owner as a role or a name, a target date, a status. An overdue action left open is a nonconformity in its own right (lesson 3.4).
| Action ID | Risk ID | Risk / hazard | Inherent | Residual | Recommended action | Owner | Target date | Status |
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Note to management (150 to 250 words)
Name the top three actions from the tracker, what each costs in rand, when it happens and who owns it, and name the site and the equipment.