Application of Failure Mode and Effect Analysis (FMEA) for audit of HACCP system

• FMEA analysis was incorporated within the verification procedure of HACCP system.
• External audits were conducted in 2 bakeries and collected results were analyzed using FAME.
• Designed method allowed precise identification of food safety risk areas in verified HACCP systems.

The aim of the study was to design the HACCP system audit method which allows precise assessment of the system functioning in practice. The method was based on specially elaborated audit questionnaire, covering all HACCP steps and principles, associated with analysis of audit findings by FMEA. External third party audits were carried out in two medium-size bakeries located in Poland. The method allowed precise identification of high and critical risks in HACCP areas of verification and recordkeeping. In view of the obligatory of HACCP system in food industry and periodically emerging food safety scandals in the EU and other countries, it appears advisable to strength control and use methods enabling precise identification of the risk. Therefore, the incorporation of FMEA analysis within the verification procedure of HACCP system may be a convenient tool for better food safety assurance. The designed method is ready to use in all types food enterprises.