QC verification schedule builder
For every PRP, OPRP and CCP, choose how it is verified, how often, by whom and on what record. The tool scores each control for risk, lists the gaps auditors usually find, and turns your matrix into a 12-month calendar you can print or download. Your work stays on this device; nothing is sent anywhere.
This free practice tool is for QC and QA supervisors, QA officers in smaller plants and HACCP team members. It follows the method taught in the FS60-0603 course: verification of the PRPs and the hazard control plan under ISO 22000:2018 (8.8), the scheme floors in FSSC 22000 Version 7 (2.5.12, routine PRP checks, for example monthly) and BRCGS Food Safety Issue 9, and frequencies set by severity, likelihood and history. It comes loaded with Isipho Beverages & Snacks (a fictional snack and beverage factory in Hammarsdale, KwaZulu-Natal) and Khanya’s Midrand distribution centre, or you can build the matrix for your own site.
How to use this tool
- Set up. Choose Isipho (14 PRPs, 4 OPRPs and 2 CCPs), Khanya’s DC (12 PRPs) or your own site. For Isipho you can start blank, fix last year’s matrix, or open the worked example. Check the people and the key dates.
- Controls and risk. Each control gets severity (1 to 3) × likelihood (1 to 3), plus 1 for a deviation, failed verification or audit finding in the last 12 months. The score gives the minimum routine frequency. The scoring table is Isipho’s procedure, marked [PJ] (professional judgement, not law): change it to your own site’s.
- Verification matrix. For each control add the activities: record review, observe the monitor, plan-to-floor check, calibration, testing, inspection, internal audit, laboratory proficiency test, validation review. Give each a frequency, an owner who does not monitor that control, and a record.
- Gap check. Read the gap list and fix every red gap. Amber items need a fix or a reason.
- Calendar. Spread the quarterly, twice-yearly and yearly items across the months, and put each one before the audit or change that relies on it.
- Print and export. Print the matrix, calendar and gap list with sign-off lines, or download them as a spreadsheet.
Best on a laptop or tablet; on a phone, tap each field to choose. Isipho, Khanya and every person named are fictional. Scores, frequencies and dates marked as case data come from the course case study, not from law. Khanya’s “monitoring now” lines are examples written for this tool. At work, use your own HACCP plan, PRP register and scheme requirements.
// The course behind this tool
Prove the controls work, not just that the forms are filled in
This tool is one practical from the QC/QA Supervisor Course for Food Manufacturing (with Introduction to HACCP) (FS60-0603). The course takes a new QC supervisor through a year at a real-feeling South African plant:
- QC team cover, skills matrices, escalation and defensible hold decisions
- The verification programme: record review for errors and falsification, calibration, laboratory and environmental monitoring
- Introduction to HACCP for supervisors: reading a plan, verifying CCPs on the floor and evaluating deviations
- KPIs and trending, CAPA and root cause analysis, complaints and recalls, supplier QA, audits and culture