What Questions Should You Ask During a HACCP Plan Review?

A HACCP (Hazard Analysis and Critical Control Points) plan isn’t something you create once and forget. It’s a living document that evolves with your products, processes, equipment, and team. That’s why regular HACCP reviews are essential—not just for compliance, but for keeping your food safety system effective and practical.

But knowing you need to review your plan is only half the battle. The real value comes from asking the right questions.

Here’s a list of key questions to guide your next HACCP plan review—and make sure your system reflects what’s really happening on the factory floor.

1. Has Anything Changed Since the Last Review?

Before diving into the technical details, start with a big-picture scan:

• Have we added any new ingredients, suppliers, or equipment?
  
  

• Have any new products or SKUs been introduced?
  
  

• Have there been staffing changes in key roles?
  
  

• Has our facility layout changed?
  
  

Even small shifts can affect hazard analysis, flow diagrams, or critical control points.

2. Are Our Flow Diagrams Still Accurate?

Flow diagrams map the journey of your product through the facility. Ask:

• Does the diagram match actual floor conditions and current processes?
  
  

• Have there been new steps added or removed (e.g., packaging updates)?
  
  

• Are inputs, outputs, and rework points clearly shown?
  
  

Walk the line physically and compare the diagram to what’s actually happening.

3. Are We Still Addressing the Right Hazards?

Your hazard analysis should reflect the real risks in your operation. Review:

• Are we still identifying all relevant biological, chemical, and physical hazards?
  
  

• Have there been any recent recalls, industry alerts, or audit findings we should factor in?
  
  

• Are supplier risks being evaluated properly (e.g., allergen control, foreign material)?
  
  

Check if any new hazards have emerged based on product changes or customer demands.

4. Are Our CCPs (Critical Control Points) Still Valid?

Some CCPs may no longer be relevant—or new ones may be needed. Ask:

• Are our current CCPs still necessary and appropriate?
  
  

• Have we validated the control measures and limits?
  
  

• Do we have scientific or regulatory support for each critical limit?
  
  

• Are monitoring methods still accurate and feasible?
  
  

Be wary of “just-in-case” CCPs that don’t serve a real function—they complicate things without improving safety.

5. Are We Monitoring Effectively and Consistently?

Monitoring only works if it’s done right. Ask:

• Are logs being completed in real time and with accuracy?
  
  

• Are staff clear on what to check and how to do it?
  
  

• Do digital or automated tools match SOP expectations?
  
  

Review real examples of logs to see if execution aligns with the written plan.

6. Are Corrective Actions Clear and Actionable?

When something goes wrong, your team should know exactly what to do. Evaluate:

• Are there clear, documented steps for each failure scenario?
  
  

• Have team members been trained to follow these steps?
  
  

• Are we documenting corrective actions fully, with follow-up?
  
  

Review any recent failures and walk through how they were handled.

7. Have We Verified and Validated Each Step?

Verification and validation are often confused—but both are important:

• Have we recently verified that monitoring, sanitation, and CCP controls are working?
  
  

• Have our critical limits been validated scientifically or with industry guidance?
  
  

Lack of documentation or outdated validation is a red flag during audits.

8. Are Our Records Complete and Audit-Ready?

Documentation is your proof. Check:

• Are records organized, legible, and time-stamped?
  
  

• Can we easily retrieve logs from a specific date, shift, or product?
  
  

• Have any logs been missed, backfilled, or duplicated?
  
  

Using digital tools can help, especially for tracking corrective actions and storing historical data. Systems like Protocol Foods make it easier to surface trends and prepare for audits without scrambling.

9. Have We Trained (and Retrained) the Right People?

Even the best HACCP plan fails without execution. Ask:

• Have all staff been trained on the parts of the plan that apply to their roles?
  
  

• Are refresher sessions held regularly or after major changes?
  
  

• Do employees understand why each step matters—not just how to do it?
  
  

Observe a few tasks being done to verify understanding matches expectations.

10. Are We Using the Review to Improve?

Beyond checking boxes, your HACCP review should identify opportunities to streamline and strengthen your food safety program:

• Can any checks be simplified or automated?
  
  

• Are there recurring issues we should address with a root cause analysis?
  
  

• Is our documentation system helping—or hindering—our process?
  
  

Reviews are a chance to eliminate guesswork, reduce burden, and close risk gaps.

Make the Most of Every Review

Whether you review your HACCP plan annually, quarterly, or after a major change, the goal isn’t just to stay compliant—it’s to stay ahead. The right questions turn a routine review into a strategic advantage.

And when you’re managing complex processes or multiple sites, a system like Protocol Foods can help centralize records, track updates, and ensure each corrective action and verification step is tied back to your plan. One or two smart adjustments after each review can make your program stronger, your audits smoother, and your team more confident.

FAQs

How often should we review our HACCP plan?

At least once a year, and any time there are significant changes to your products, processes, suppliers, or facility.

Who should be involved in the review?

Include your HACCP team leader, QA/food safety lead, supervisors, and representatives from operations and maintenance. Diverse input leads to a better plan.

Do we need to revise the HACCP plan even if nothing has changed?

Not always—but a review still needs to be documented to show that an evaluation occurred.

What happens if we identify a new hazard during the review?

Update the hazard analysis, determine if a CCP is needed, and revise procedures and training as necessary. Document all changes.

Can digital systems help manage HACCP reviews?

Yes. Digital platforms allow you to track plan versions, log changes, schedule reminders, and ensure that all documentation is centralized and easy to access during audits.