How Should a Company Prepare for an Unannounced FSSC 22000 Audit?

As part of the FSSC 22000 Version 6 requirements, at least one unannounced audit must occur during every 3-year certification cycle.
That means: the auditor can walk in at any time—with no warning.

So how do you keep your team and your facility ready at all times without compromising operations or quality?

Here’s a breakdown of how to build a state of permanent audit readiness and avoid audit surprises turning into audit failures.

🧠 What Is an Unannounced FSSC 22000 Audit?

• A full system audit with no advance notice

• Focuses on the same elements as a regular surveillance audit:

  • ISO 22000 FSMS

  • PRP implementation (e.g. ISO/TS 22002-1)

  • FSSC additional requirements

• Can be triggered randomly or due to:

  • Prior non-conformances

  • Complaints or food safety incidents

  • Market recalls or GFSI alerts

✅ Daily Practices to Stay Audit-Ready

1. Keep Documentation Updated at All Times

• Food Safety Manual

• HACCP Plan & flow diagrams

• Monitoring records (CCPs, OPRPs, cleaning logs)

• Supplier approval list

• Internal audit and management review records

• Corrective & preventive actions (CAPA)

2. Conduct Monthly Internal Spot Checks

• Mock mini-audits using the FSSC checklist

• Rotate between departments (receiving, processing, packaging, etc.)

• Include document review + site walkthrough

3. Train All Staff on Basic Audit Etiquette

• Staff should know:

  • What FSSC 22000 is

  • Their food safety responsibilities

  • How to answer auditor questions honestly and confidently

• Provide short refresher training every 3–6 months

4. Ensure Personal Hygiene Compliance

• Hairnets, gloves, PPE worn properly

• Handwashing signage visible and enforced

• Access control between hygiene zones clearly followed

5. Keep the Premises Audit-Ready

• No clutter, no expired chemicals, no broken tools lying around

• Calibration stickers visible and in date

• Cleaning schedules followed and logs filled accurately

🛠 Procedures That Should Always Be Ready to Show

• Product traceability (forward and backward)

• Food defense and food fraud vulnerability assessment

• Pest control trend reports

• Recall and withdrawal procedure

• Environmental monitoring results (if applicable)

• Allergen management plan

• Equipment maintenance and cleaning validation

🔁 Best Practices for Team Readiness

Create an “Unannounced Audit Response SOP”

• Includes steps like:

  • Notify QA manager and site leadership

  • Escort auditor and provide PPE

  • Assign audit support team roles (documentation, walkthrough, etc.)

• Keep this SOP visible in QA office or main board

Conduct Unannounced Mock Audits Internally

• Let department heads experience the pressure

• Help teams improve real-time response without rehearsal

Keep an “Audit Kit” Prepared

• With items like:

  • Latest org chart

  • Floor plan

  • Updated training matrix

  • Pen, highlighter, spare copies of HACCP plan

❗ Common Mistakes That Lead to Non-Conformance

• ❌ Backdated or falsified records

• ❌ Staff unaware of basic food safety rules

• ❌ Incomplete traceability during product recall test

• ❌ Cleaning logs filled “at once” instead of real-time

• ❌ Outdated procedures or SOPs still in circulation

• ❌ Critical deviations not followed up with CAPA

📌 What to Do When an Auditor Arrives

• Stay calm—audits are about verifying systems, not catching individuals

• Notify internal teams via pre-set communication (e.g. WhatsApp group)

• Greet auditor professionally and explain facility rules

• Provide requested documents promptly

• Ensure all answers are truthful and evidence-based

🏁 Final Thoughts

Unannounced audits are not about luck—they’re about discipline.
With a strong food safety culture, solid housekeeping, and real-time compliance, your team can handle any audit—expected or not.

Being always-ready not only protects your FSSC 22000 certification, but also builds trust with customers, regulators, and stakeholders.

Need help preparing your team for an FSSC 22000 unannounced audit?
At CAYS Scientific, we offer internal audit simulations, food safety gap analysis, and training programs to make your factory “audit-proof” all year round. Reach out today to stay 100% ready.