An factory audit is to understand what processes are used in the factory to manufacture and control what is manufactured. Sometimes it is done by the company itself, sometimes by a business partner or a third-party organization.

In particular, food factories need thorough quality control and strict hygiene management to provide safe food products.

This article will help you understand the importance and effectiveness of audits. If you work in a food factory or are about to undergo an audit, please read this article for reference.

1. Contents And Necessity Of Food Factory Audits

First, we will explain the contents and necessity of audits conducted in food factories. What are the benefits of conducting audits?

1-1. Food factories require high safety standards.

In food factories, large quantities of food products are manufactured and shipped nationwide every day. Most of the food produced in factories is processed or frozen food, and most of it is only heated up before being put into consumers’ mouths. That is why a high level of safety is required. If foreign matter or bacteria were to get mixed in during the manufacturing process, or if substandard products were to be shipped without being noticed, it could lead to a major accident. However, if the same work is done day in and day out, “habituation” will inevitably occur, and product control and manufacturing may become sloppy. To prevent this, it is necessary to conduct “audits” to check product management and manufacturing processes.

1-2. Audits are also effective in preventing accidents in advance

Once an accident occurs in a food factory, not only are their many victims but also trust is lost. It will take many years to regain the trust once lost, and in some cases, it may be difficult for the factory to survive. Therefore, it is important to prevent accidents before they happen. For this purpose, external audits can be very effective.

2. Types Of Audits Conducted In Food Factories Explained

This section describes the types of audits performed in food factories. It is important to conduct audits in an appropriate manner according to the situation and necessity.

2-1. Internal Audit

Internal audit is an audit conducted by “auditors” consisting of personnel working in the factory. Internal audits mainly check whether work is being performed in accordance with “manuals” and “business regulations” and whether work processes meet ISO requirements. While it is possible to check necessary items in a short period of time, there is a possibility that the checks will be carried out in a haphazard manner, so it is advisable to combine the internal audit with other auditing methods.

2-2. Second-Party Audit

Second-party audits are conducted by auditors consisting of employees of the company’s business partners, contractors, parent company, or other companies with which the company has a relationship. The main purpose of the audit is to determine whether the company meets the level required by the business partner. Compared to internal audits, these audits are more impartial because they involve outside eyes.

2-3. Third Party Audit

Third-party audits are conducted by a third-party organization that has no vested interest in the factory, such as an ISO auditor. This is often done when acquiring international food safety standards or renewing certifications. The fact that a third party has no vested interest in the factory may reveal hidden irregularities. On the other hand, if the audit is not conducted by an auditor who does not have specialized knowledge, it will be a mere formality.

3. Points To Keep In Mind When Auditing A Food Factory

Lastly, we will explain some points to keep in mind during an audit of a food factory. Please refer to it.

3-1. Are the checkpoints covered?

Food factory audits have semi-manualized checkpoints such as “factory entry control,” “checking work processes,” “cleanliness of the factory,” etc. If these checkpoints are not covered, there is no meaning to the audit. If these are not covered, the audit is meaningless. In particular, internal audits tend to be “haphazard” if there is not enough time or if work is too busy.

3-2. Set a budget for third-party audits

Third-party audits may be requested for a fee. If a third-party audit is not conducted for a long period of time due to “lack of budget” or “lack of time,” the audit may become a mere formality. It is also important to keep the budget ahead of time in order to conduct audits on a regular basis.

3-3. Second-party audits should be impartial

Second-party audits are conducted by a department that has a vested interest in the factory. Although it is often thought to be more impartial than internal audits, there is a possibility of cover-ups or other problems that may occur when interests are aligned. It is important to maintain impartiality in second-party audits as in internal audits.

4. Frequently Asked Questions About Food Factory Audits

Here are some frequently asked questions about food factory audits.

Q. How often should food factory audits be conducted?

A. There is no clear rule, but it is generally recommended to conduct an internal audit once every six months to once a year, and a bilateral audit once a year.

Q. Are unannounced audits more effective?

A. If it is known in advance that an audit will be conducted, there may be some concealment of irregularities. However, food factories are sometimes structured to prevent unintentional entry of outsiders. If you are going to conduct unannounced audits, do so to the extent that it does not affect the factory’s operations.

Q. Can I request a specialized organization to conduct a third-party audit?

A. Yes. Some organizations, such as the Japan Food Inspection Corporation, conduct audits to prevent accidents in food factories. Requesting them is one way to do so.

Q. Isn’t an internal audit alone sufficient to audit a food factory?

A. Yes, if there is a period of checking to ensure that they do not become a formality, they can be effective to a certain extent.

Q. Are there any penalties for not auditing a food factory?

A. Depending on the international standards you have obtained, there may be penalties such as disqualification if you do not undergo an audit. Please check.

Conclusion

In this issue, we have explained the effectiveness, necessity, and types of food factory audits. Food factories require the highest level of safety and quality control among factories. It is important to think of audits not as “something troublesome” but as “something necessary to prevent accidents,” and to undergo them regularly and thoroughly.