Section 7: 30-Day Preparation Timeline Plan

A successful audit requires rigorous, structured schedules leading up to the audit day. Use the timeline tabs below to coordinate corrective actions and verify systems.

Days 30 to 15: Structural Fixes & Baseline Verification
  • Resurface concrete floors in Line M1/M3 frying areas. Clean out cracks and overlay with polyurethane cement overlay.
    Critical
    QA / Maintenance
  • Install screen guards on the exterior exhaust wall portals (large fan housing). Seal wall gaps with silicone.
    Critical
    Maintenance
  • Establish the Allergen Control Map and segregate raw peanut storage to Bay 4 bottom racks. Clean up overlapping items.
    Major
    Warehouse Lead
  • Review all SKU product labels for ingredient accuracy and correct allergen warnings (Wheat, Soy, Milk, Peanuts).
    Major
    QA Manager
  • Purchase hands-free handwash sinks or retrofit existing sinks with foot-pedal/photo-sensor triggers. Stock dispensers.
    Minor
    Procurement
Days 14 to 8: Deep Cleaning & Document Compilation
  • Clean equipment frameworks, specifically scraping carbon/oil buildup from black painted steel support beams on Line M1 and M3.
    Major
    Sanitation Crew
  • Compile the Master Document binder containing all policies (Section 2) and forms (Section 3). Audit last 3 months of logs.
    Major
    QA Doc Controller
  • Walk facility with pest technician. Verify all traps match layout map. Verify no activity on interior glue traps.
    Major
    QA Manager
  • Execute a plant-wide training refresher on personal hygiene, allergen separation, and handwashing protocols (SOP-001/002).
    Minor
    QA Manager
Days 7 to 2: Verification Audits & Mock Exercises
  • Execute Mock Recall Exercise (GMP-SOP-012). Trace seasoning or flour lot back to supplier and forward to customer. Target time < 4 hours.
    Critical
    QA Manager / Warehouse
  • Conduct Internal GMP Audit (GMP-F-021) using Mérieux Auditor Checklist guidelines (Section 4). Document all final gaps.
    Major
    QA Auditor
  • Perform tool and parts audit in maintenance shop. Move welding sets and loose hardware out of food packaging rooms.
    Major
    Maintenance Lead
  • Calibrate scale balances and check thermometer accuracy in ice baths. File calibration logs on GMP-F-016.
    Minor
    QA Staff
24 Hours Before Audit: Operational Lockdown
  • Deep-clean all floor drains (removable baskets scrubbed). Empty plant trash bins and replace with liners.
    Major
    Sanitation Crew
  • Verify handwash station supplies: paper towels, antibacterial soap, hand sanitizer fully stocked at every sink.
    Major
    Production Supervisor
  • Purge all cardboard boxes, loose paper, or personal items from equipment surfaces. Clean metal detector hopper.
    Major
    Production Supervisor
  • Check locked reject boxes at metal detectors. Empty rejects and verify key is held by QA.
    Minor
    QA Manager
  • Verify visitor frock inventory. Prepare clean visitor safety glasses, earplugs, and hairnets near lobby reception.
    Minor
    Receptionist / QA
Audit Day Protocol: Execution & Professional Escort
  • Audit Opening Meeting: Greet Mérieux auditor. Register in visitor log, check health questionnaire, issue gowning kit.
    Protocol
    Recall Committee
  • Verification at Entry: Ensure auditor wears hairnet, beard net (if applicable), clean visitor coat, and washes hands.
    Critical
    QA Escort
  • Plant Tour: Accompany auditor along the designated floor path. Never leave the auditor alone on the floor.
    Protocol
    QA Manager / Ops Director
  • Doc Review: Present binders in order. Open Section 1 Master Index when document records are requested.
    Protocol
    QA Manager
  • Correct on the Spot: If the auditor points out a minor finding (e.g. employee hairnet out of place), correct it immediately and record.
    Tactic
    Plant Leadership