GF GMP Internal Audit Small Bakery

• Document No.

• Audit Title

• Client / Site

• Conducted on

  Date

• Prepared by

• Location
  Address

• Personnel

PEOPLE

Compliance

• Hairnets - Are all employees wearing hairnets correctly ( covers hair and ears ). Are beard snoods being worn appropriately as required

  1

  2

  3

  4

  5

• Uniforms - Are all employees adhering to uniform policy, are uniforms pocket-less, wearing correct uniform, clean with no rips or holes

  1

  2

  3

  4

  5

• Footwear - Is clean and appropriate footwear being worn by all

  1

  2

  3

  4

  5

• Hearing Protection - clean hearing protection being worn by all ( as required )

  1

  2

  3

  4

  5

• Personal Items - No personal items found on line, no personal mobile phones, nothing in toolboxes or bum bags

  1

  2

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  5

Personal Hygiene

• Illness - Employees do not have evidence of Cold / Flu or Viruses

  1

  2

  3

  4

  5

• Band Aids - Employees do not have open cuts / abrasions or wounds, only metal detectable band aids being worn?

  1

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  3

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  5

• Nails - No evidence of false nails / nail polish being worn in the manufacturing area

  1

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  5

• Jewellery - Only plain wedding bands to be worn ( Medical, Ethnic, Religious by written permission only)

  1

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  5

• Eating / Drinking - No evidence of eating or drinking ( other than authorised water bottles / water fountain )

  1

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  5

• Hand Washing - Hands Washed Upon Entry and sanitised or gloves changed at appropriate frequency

  1

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  5

• Contractors and Visitors are GMP compliant I.e. Hairnets, attire, snood

  1

  2

  3

  4

  5

PEST CONTROL

Pest Control

• Pest activity - no evidence of pest activity in the area, I.e. insects, webbing, tracks, droppings or feathers

  1

  2

  3

  4

  5

• Pest exclusion - doors, walls, ceilings have adequate seals and are kept closed i.e. no light coming through doors and windows, sealed pest stripping under doors

  1

  2

  3

  4

  5

• Pest bait and monitoring system are adequate in number, monitored and controlled

  1

  2

  3

  4

  5

• Insectocutors are operational and in good working order

  1

  2

  3

  4

  5

• Pest sightings log / register is available and in use

  1

  2

  3

  4

  5

• No evidence of infested raw materials

  1

  2

  3

  4

  5

BUILDING AND EQUIPMENT

Walls / Floors / Ceiling

• Walls / Floors / Ceiling - are all surrounding walls, floors and ceilings clean in good condition

  1

  2

  3

  4

  5

• Walls, ladders and steps are free of clutter

  1

  2

  3

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  5

• Are all lights covered with shatterproof covering and in good working order

  1

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  5

• Are any ceiling vents or wall / floor vents or fans clean and in good condition

  1

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  5

• Drains are clean and free from any objectionable odours, drains have removable grates

  1

  2

  3

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  5

• No evidence of condensation or water dripping from ceiling

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  5

• No old or redundant equipment is clean and stored in such a way so as not to contaminate product or harbour any pests left in Manufacturing areas

  1

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  5

• No products / WIP / Raw materials are stored directly against the wall allowing for pest harbourage

  1

  2

  3

  4

  5

Building Cleanliness

• Bins are in adequate numbers, tidy and regularly emptied

  1

  2

  3

  4

  5

• No objectionable odours, smoke, dust or other airborne contaminants in the factory

  1

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  3

  4

  5

• Is the correct colour coded cleaning equipment in good condition and being used for the right purpose, is there adequate cleaning equipment in the area

  1

  2

  3

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  5

• Rags are not in use, only food grade, disposable, coloured cleaning clothes are available and use

  1

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  5

• Cleaning chemicals are being used correctly and all bottles and containers are labelled

  1

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  5

INCOMING GOODS, RAW MATERIALS, STORES, WEIGH UP

Raw Material Handling

• Allergen ingredients are stored and labelled correctly (in designated labelled areas) and signs displayed where applicable

  1

  2

  3

  4

  5

• Are pallets in acceptable condition i.e. not broken, not double stacked

  1

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  5

• Pallets are not being stored on the floor, racking being used

  1

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  5

• Plastic pallets skirts are being used inside warehouse, weigh up and factory areas

  1

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  5

• Is the FIFO system being followed and green 'approved' stickers evident on each pallet

  1

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  5

• All incoming products is free of infestation, damage or objectionable odours before transferring to storage

  1

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  5

• Packaging materials are stored on appropriate racking, not being stored on the floor

  1

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  5

• The only forklifts being used are gas fuelled and not diesel, in good working order and do not have evidence of foreign material or personal items

  1

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  5

• Ingredient tubs are appropriately labelled, labels are in good condition, ingredients are being stored in the correct tubs, there is no evidence of cross contamination

  1

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  3

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  5

• Damage pallets and crates are removed from within Manufacturing and distribution areas

  1

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  3

  4

  5

Cleanliness And Hygiene

• Cleanliness of the line, above the line and food contact surfaces is acceptable

  1

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  3

  4

  5

• Off-line cleanliness i.e. Under equipment, walls, floors and around supports a clean and free from build up

  1

  2

  3

  4

  5

• Hoses are cleaned and stored appropriately

  1

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  3

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  5

• Is the 'Clean As You Go' policy evident, no evidence of spills not cleaned up, no pooled water

  1

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  5

• Cleaning chemical cage is locked and all chemicals appropriately labelled

  1

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  5

Foreign Material Control

• Areas above mixing / ingredients tanks i.e. Pipe work is in good condition, no condensate, water dripping, no temporary repairs, no disintegrating lagging, no foreign material above the mixers / brew tanks that has the potential for contamination

  1

  2

  3

  4

  5

• Any unused pipe work has its ends sealed to prevent pest harbourage

  1

  2

  3

  4

  5

• No temporary repairs have been made using cable ties, string or tape

  1

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  3

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  5

• Equipment is in an acceptable condition, no evidence of paint chipping or broken parts

  1

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  3

  4

  5

• All guards are in place and in good condition, no broken chipped or cracked Perspex

  1

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  5

• Sieves, screens and filters are being used appropriately, correct sizes being used and sieve is in good condition without tears / holes evident. Screens and filters are in place

  1

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  5

• Nothing stored above food stream or on top of raw materials or equipment

  1

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  5

• No foreign material seen in area either on or off-line i.e. wood, plastic, swarf, nuts, bolts, etc

  1

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  3

  4

  5

Dropped And Non Conforming Product

• Any non conforming product is isolated, labelled and recorded to prevent it being dispatched without QA approval

  1

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  5

• Any dropped product disposed of immediately

  1

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  5

Calibration

• Scales are clean, level and have been calibrated as per schedule. Labelled with calibration date

  1

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  5

• Thermometers are clean (sanitised if needed) and calibrated according to site schedule

  1

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  5

Tools

• Knives are approved type, in good condition, clean and stored appropriately

  1

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  5

• Tools are being stored in toolbox or in allocated areas and not being stored on equipment

  1

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  5

Process Control

• Latest version of process control forms are in place, being completed properly and on time

  1

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  3

  4

  5

• All documents are controlled and approved version numbers and date by QA

  1

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  3

  4

  5

• No pins, staples or paper lips are found inside manufacturing

  1

  2

  3

  4

  5

• Only metal detectable pens are being used in the area and are secured

  1

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  5

• Work stations are neat and tidy

  1

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  5

MIXING, DIVIDING, ROUNDER, INTERMEDIATE PROOVER, MOULDING

Raw Materials Handling

• Ingredient tubs are in good condition, no chips or cracks, ingredient tubs are clean and appropriate for use. All sealed with lids

  1

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  4

  5

• All ingredient tubs are appropriately labeled. Labels in good condition. Ingredients are being stored in the correct tubs, no evidence of cross contamination.

  1

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  4

  5

• Plastic pallet skirts are being used inside weigh up and factory areas

  1

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  4

  5

• No items are being stored on top of ingredients or ingredient bags. Ingredient bags are not being left open

  1

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  5

• Ingredient tubs, bread tins, or other food contact equipment is not being stored in direct contact with the floor

  1

  2

  3

  4

  5

Allergens

• Allergen ingredients are stored and labelled correctly ( in designated labeled areas ) and signs displayed where applicable

  1

  2

  3

  4

  5

• Allergens are being handled correctly I.e. Correct colour coding

  1

  2

  3

  4

  5

• Allergen cleans are being completed correctly, no evidence of allergens left on the line after these cleans

  1

  2

  3

  4

  5

Cleanliness And Hygiene

• Cleaning - is there any evidence of previous product on the line with the potential to cause cross contamination

  1

  2

  3

  4

  5

• Walls / floors / ceilings - are all surrounding walls, floors, and ceilings clean and in good condition

  1

  2

  3

  4

  5

• Cleanliness of the line, above the line and food contact surfaces is acceptable

  1

  2

  3

  4

  5

• Is the clean as you go policy evident - no evidence of spills not cleaned up, no pooled water

  1

  2

  3

  4

  5

• Are all out of the way areas I.e. Under equipment, corners, under tables, door handles, switches etc clean and tidy

  1

  2

  3

  4

  5

• Off line cleanliness I.e. Under equipment, walls floors and are puns supports are clean and free from build up

  1

  2

  3

  4

  5

• Hoses are cleaned and stored correctly

  1

  2

  3

  4

  5

Foreign Material Control

• Areas above mixing / ingredient tanks I.e. Pipe work is in good condition, no condensate, water dripping, no temporary repairs, no disintegrating lagging. No foreign material above the mixers / brew tanks that has the potential for contamination

  1

  2

  3

  4

  5

• Any unused pipe work has its ends sealed or capped to prevent pest harbourage

  1

  2

  3

  4

  5

• No temporary repairs have been made using cable ties, string or tape

  1

  2

  3

  4

  5

• Equipment is in acceptable condition, no evidence of paint chipping, broken parts

  1

  2

  3

  4

  5

• All guards are in place and in good condition. No broken, chipped or cracked Perspex.

  1

  2

  3

  4

  5

• Sieves, screens and filters are in being used appropriately, correct sieve sizes being used and sieve is in good condition without tears / holes evident. Screens and filters are in place

  1

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  3

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  5

• Conveyor belts and intermediate Proover pockets are clean, free from previous product and in good condition

  1

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  5

• Conveyor belts and intermediate Proover pockets are clean, free from previous product and in good condition

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  5

• Tin cleaner is operational and working effectively

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  5

• Dropped product ( unpackaged, finished product, WIP, or raw material) is discarded as waste immediately

  1

  2

  3

  4

  5

• Tools- are being stored in toolbox or allocated areas and are not being stored on equipment

  1

  2

  3

  4

  5

• Nothing stored above food stream or on top of raw materials or equipment

  1

  2

  3

  4

  5

• Oil and water spray bottles are labelled and not being stored on equipment

  1

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  3

  4

  5

• No foreign material seen in area either on or off line I.e wood, plastic, swarf, nuts, bolts, etc

  1

  2

  3

  4

  5

Process Control

• Latest version of process control forms are in place and being completed properly and on time

  1

  2

  3

  4

  5

• All documents are controlled and approved version numbers and date by QA

  1

  2

  3

  4

  5

• No pins, staples or paper clips are found inside manufacturing areas

  1

  2

  3

  4

  5

• Only metal detectable pens are being used in the area and are secured

  1

  2

  3

  4

  5

• Work stations are neat and tidy

  1

  2

  3

  4

  5

PROOVER, OVEN, COOLER

Raw Material Handling

• Ingredient tubs are in good condition, no chips or cracks, ingredient tubs are clean and appropriate for use. All sealed with lids

  1

  2

  3

  4

  5

• All ingredient tubs are appropriately labelled. Labels are in good condition. Ingredients are being stored in the correct tubs, no evidence of cross contamination

  1

  2

  3

  4

  5

• No items are being stored on top of ingredients or ingredient bags. Ingredient bags are not being left open

  1

  2

  3

  4

  5

• Ingredient tubs, bread tins, or other food contact equipment is not stored in direct contact with the floor

  1

  2

  3

  4

  5

Allergens

• Allergen ingredients are stored and labelled correctly ( in designated labelled areas ) and signs displayed where applicable

  1

  2

  3

  4

  5

• Allergens are being handled correctly I.e correct colour coding

  1

  2

  3

  4

  5

• Allergen cleans are being completed correctly, no evidence of allergens left on the line after these cleans

  1

  2

  3

  4

  5

Cleanliness And Hygiene

• Cleaning - is there any evidence of previous product on the line with the potential to cause cross contamination I.e. Seeds

  1

  2

  3

  4

  5

• Cleanliness of the line, above the line and food contact surfaces is acceptable

  1

  2

  3

  4

  5

• Off line cleanliness I.e under equipment, walls, floors and around supports are clean and free from build up

  1

  2

  3

  4

  5

• Are all out of the way areas I.e. Under equipment, corners, under tables, door handles, switches, etc are clean and tidy

  1

  2

  3

  4

  5

• Is the clean as you go policy evident - no evidence of spills not cleaned up, no pooled water

  1

  2

  3

  4

  5

• Hoses are cleaned and stored appropriately

  1

  2

  3

  4

  5

Foreign Material Control

• Tools - are being stored in toolbox or allocated areas and are not being stored on equipment

  1

  2

  3

  4

  5

• Dropped product ( unpackaged, finished product, WIP or raw material ) discarded immediately as waste

  1

  2

  3

  4

  5

• No foreign material seen in the area either nor off line I.e wood, plastic, swarf, nuts, bolts, etc

  1

  2

  3

  4

  5

• Nothing stored above food stream or on top of raw materials or equipment

  1

  2

  3

  4

  5

• No evidence of charcoal build up in tins or oven lids

  1

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  5

• Cooler shelves are visibly clean and free of debris

  1

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  5

• Equipment is in acceptable condition, no evidence of paint chipping, broken parts

  1

  2

  3

  4

  5

• No temporary repairs have been made using cable ties, string or tape

  1

  2

  3

  4

  5

• Conveyor belts and depanner cups are clean, free from previous product and in good condition

  1

  2

  3

  4

  5

• All guards are in place and in good condition. No broken, chipped or cracked Perspex

  1

  2

  3

  4

  5

Process Control

• Latest version of process control forms are in place and being completed properly and on time

  1

  2

  3

  4

  5

• All documents are controlled and approved version numbers and date by QA

  1

  2

  3

  4

  5

• No pins, staples or paper lips are found inside manufacturing areas

  1

  2

  3

  4

  5

• Only metal detectable pens are being used in the area and are secured

  1

  2

  3

  4

  5

• Work stations are clean and tidy

  1

  2

  3

  4

  5

SLICING

Raw Material Handling

• Damaged crates we removed from the manufacturing and distribution areas

  1

  2

  3

  4

  5

• Packaging materials are stored on appropriate racking, not being stored on the floor

  1

  2

  3

  4

  5

• Food contact equipment is not stored in contact with the floor

  1

  2

  3

  4

  5

Cleanliness And Hygiene

• Cleanliness of the line, above the line and food contact surfaces is acceptable

  1

  2

  3

  4

  5

• Conveyor belts are clean, free from previous product and in good condition

  1

  2

  3

  4

  5

• Cleaning chemicals are appropriately labelled

  1

  2

  3

  4

  5

• Cleaning - is there any evidence of previous product on the line with the potential to cause cross contamination I.e. Seeds

  1

  2

  3

  4

  5

• Are all out of the way areas I.e under equipment, corners, under tables, door handles, switches, etc are clean and tidy

  1

  2

  3

  4

  5

• Off line cleanliness I.e under equipment, walls floors and around supports are clean and free from build up

  1

  2

  3

  4

  5

Foreign Material Control

• Equipment is in acceptable condition, no evidence of paint chipping, broken parts

  1

  2

  3

  4

  5

• No temporary repairs have been made using cable ties, string or tape

  1

  2

  3

  4

  5

• All guards are in lace and in good condition. No broken, chipped or cracked Perspex

  1

  2

  3

  4

  5

• Hoses are cleaned and stored appropriately

  1

  2

  3

  4

  5

• All operators handling non packaged finished products are wearing gloves. All gloves are in good condition, are clean, changed regularly and are free of rips or tears

  1

  2

  3

  4

  5

• Tools - are being stored in toolbox or allocated areas and are not being stored on equipment

  1

  2

  3

  4

  5

• Nothing stored above food stream or on top of raw materials or equipment

  1

  2

  3

  4

  5

• No foreign material seen in aa either on or off line I.e wood, plastic, swarf, nuts, bolts etc

  1

  2

  3

  4

  5

• Oil and water spray bottles are labelled and not being stored on equipment

  1

  2

  3

  4

  5

• No finished product containers e.g bread bags are used to store anything on site except for what it is intended for

  1

  2

  3

  4

  5

Dropped And Non Conforming Product

• Dropped product ( finished product, WIP or raw material ) is discarded immediately as waste

  1

  2

  3

  4

  5

• Any non conforming product is isolated, labelled and recorded to prevent it being dispatched without QA approval

  1

  2

  3

  4

  5

• Unbagged finished product shall not be left standing for extended periods exposed. Naked bread to be stored in dry and clean paper lined crates, and be at least one crate of the floor

  1

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  5

• Bagged finished product is inspected and thrown away if damaged

  1

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• Bagged finished product shall not be left standing for extended periods of time in open areas

  1

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  3

  4

  5

Building Cleanliness

• Bins are in adequate numbers, are tidy and are emptied reglularly

  1

  2

  3

  4

  5

• The correct colour coded cleaning equipment is being used, is in good condition, is being used for the correct purpose and is in adequate supply

  1

  2

  3

  4

  5

• Cleaning chemicals being used correctly, all bottles and containers are labelled

  1

  2

  3

  4

  5

Process Control

• Latest version of process control forms are in place and are being completed properly and on time

  1

  2

  3

  4

  5

• All documents a controlled and approved version numbers and date by QA

  1

  2

  3

  4

  5

• No pins, staples or paper lips are found inside manufacturing areas

  1

  2

  3

  4

  5

• Only metal detectable pens are being used in area and are secured

  1

  2

  3

  4

  5

• Workstations are neat and tidy

  1

  2

  3

  4

  5

Metal Detection / Date Coding

• Metal detectors shall be installed on each line and shall be checked as per site procedure for rejection and timing

  1

  2

  3

  4

  5

• Metal detector bins or cages are in place and locked

  1

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  3

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  5

• All finished product is date coded correctly and legibly. Both primary and secondary packaging where applicable

  1

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  3

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  5

Calibration

• Scales a clean, level and have been calibrated sis per the schedule. Labelled with calibration date

  1

  2

  3

  4

  5

• Thermometers are clean ( sanitised if needed ) and calibrated according to site schedule

  1

  2

  3

  4

  5