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HACCP plan template: hazard analysis and CCP worksheet
A HACCP plan is the written record of how a food plant controls the significant food safety hazards in one product or group of products: which hazards matter at which step, where the critical control points (CCPs) are, and for each CCP the critical limit, monitoring, corrective action, verification and records. This template follows the 12 steps of the Codex Alimentarius General Principles of Food Hygiene (CXC 1-1969, revised 2022): five preliminary steps (team, product description, intended use, flow diagram and its check on site), then the seven principles. The Excel version scores each hazard on a severity and likelihood grid your team sets, works the Codex four-question decision tree into CCP or not, numbers the CCPs, checks that every significant hazard has a control and every CCP row is complete, lists the allergens on each line that a product does not contain, and dates every verification activity. The PDF has the paper forms, the decision tree in plain words and a worked example for a cooked and chilled sauce. It is a worksheet, not a certified plan: it does not replace HACCP training, a qualified person or the rules of your market.
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
Fields for site, product, plan version and approver, a HACCP team table with training and role, and boxes for the product description, intended use and users, scope and prerequisite programmes.When to use it
When to use a HACCP plan worksheet
- Writing the first HACCP plan, or the hazard analysis behind a US food safety plan, for a new product or line.
- Reviewing a plan after a change of recipe, supplier, equipment, process or pack, or after a deviation or a recall.
- The yearly review, to check every CCP still has a measurable limit, monitoring that would catch a deviation in time and someone verifying it.
- Before a customer or certification audit, to find the missing steps, hazards and records before the auditor does.
How to fill it in
- 1
Start with the prerequisite programmes and the team
HACCP sits on top of good hygiene and manufacturing practices: cleaning, pest control, hygiene, maintenance, supplier approval and training must already work. Name a team that covers production, maintenance, QA and cleaning, bring in outside microbiology help if you lack it, and record each member's HACCP training.
- 2
Describe the product and how it is really used
Ingredients, pH and water activity, allergens, the heat step, the pack atmosphere, shelf life and storage. Then the intended use and the misuse you know about: a sauce meant to be heated that people eat cold is treated as ready to eat.
- 3
List the steps, then walk them on every shift
Number every step with what comes in (ingredients, packaging, water, air, rework) and what leaves. Walk the line on days, nights and during cleaning, and correct the list. A step missing from the diagram is a step nobody analysed.
- 4
Analyse the hazards step by step
At each step, write each biological, chemical, allergen and physical hazard with its cause. Score severity and likelihood 1 to 3 on the grid your team sets (the example marks a score of 4 or more as significant), give the reason and name the control measure.
- 5
Decide the CCPs with the four questions
For each significant hazard: can a prerequisite programme control it here (not a CCP)? Is there a control measure at this step? Will a later step control it (then that step is the CCP)? Can this step control it (a CCP)? If no step can, change the process. The sheet numbers the CCPs.
- 6
Fill the CCP table, validate, then verify
For each CCP: a measurable or observable critical limit and the evidence behind it, what is monitored, how, how often and by whom, the corrective action, the verification and the record. Validate the plan before you use it, then schedule the record reviews, calibrations, tests and audits.
The 12 steps
The Codex 12 steps and where each one goes
Steps 1 to 5 prepare the ground; steps 6 to 12 are the seven HACCP principles (Codex CXC 1-1969, section 19), in plain words.
| Step | What you do | Sheet in this template |
|---|---|---|
| 1. Assemble the HACCP team and set the scope | Bring together people who know production, maintenance, quality, cleaning and microbiology, get outside help where you lack it, and write down which products and steps the plan covers. | Team and product |
| 2. Describe the product | Record what affects safety: ingredients, pH, water activity, preservatives, allergens, heat or other treatment, packaging, shelf life, storage, distribution and any limits a regulator has set. | Team and product |
| 3. Identify intended use and users | How the next business or the consumer uses it, known misuse, and whether vulnerable groups such as hospital patients will eat it. | Team and product |
| 4. Construct the flow diagram | Every step in order, with the ingredients, packaging, water, air, rework and waste going in and out. | Process steps |
| 5. Confirm the flow diagram on site | Walk the process during every shift and hour of operation and correct the diagram. | Process steps |
| 6. Hazard analysis (principle 1) | List the hazards at each step, decide which are significant from their severity and likelihood without control, and identify the control measures. | Significance, Hazard analysis |
| 7. Determine the CCPs (principle 2) | Use the decision tree for each significant hazard. A CCP is a step where control is essential and a failure could make the food unsafe. | Hazard analysis |
| 8. Establish validated critical limits (principle 3) | A measurable or observable value (a time and temperature, a pH, a detector that rejects test pieces) that separates safe from unsafe, with evidence that it controls the hazard. | HACCP plan |
| 9. Establish monitoring (principle 4) | What, how, how often and who, so a deviation is found in time to hold the product. Continuous where possible. | HACCP plan |
| 10. Establish corrective actions (principle 5) | Written in advance for each CCP: restore control, hold and decide on the affected product, find the cause, record it. | HACCP plan |
| 11. Validate the plan, then verify it (principle 6) | Evidence before use that the plan can control the hazards, then record reviews, calibration, testing and audits by someone other than the person monitoring. | Verification |
| 12. Documentation and records (principle 7) | Keep the plan, its scientific basis and the records it produces: monitoring, deviations, corrective actions and verification. | HACCP plan and every sheet |
1. Assemble the HACCP team and set the scope
- What you do
- Bring together people who know production, maintenance, quality, cleaning and microbiology, get outside help where you lack it, and write down which products and steps the plan covers.
- Sheet in this template
- Team and product
2. Describe the product
- What you do
- Record what affects safety: ingredients, pH, water activity, preservatives, allergens, heat or other treatment, packaging, shelf life, storage, distribution and any limits a regulator has set.
- Sheet in this template
- Team and product
3. Identify intended use and users
- What you do
- How the next business or the consumer uses it, known misuse, and whether vulnerable groups such as hospital patients will eat it.
- Sheet in this template
- Team and product
4. Construct the flow diagram
- What you do
- Every step in order, with the ingredients, packaging, water, air, rework and waste going in and out.
- Sheet in this template
- Process steps
5. Confirm the flow diagram on site
- What you do
- Walk the process during every shift and hour of operation and correct the diagram.
- Sheet in this template
- Process steps
6. Hazard analysis (principle 1)
- What you do
- List the hazards at each step, decide which are significant from their severity and likelihood without control, and identify the control measures.
- Sheet in this template
- Significance, Hazard analysis
7. Determine the CCPs (principle 2)
- What you do
- Use the decision tree for each significant hazard. A CCP is a step where control is essential and a failure could make the food unsafe.
- Sheet in this template
- Hazard analysis
8. Establish validated critical limits (principle 3)
- What you do
- A measurable or observable value (a time and temperature, a pH, a detector that rejects test pieces) that separates safe from unsafe, with evidence that it controls the hazard.
- Sheet in this template
- HACCP plan
9. Establish monitoring (principle 4)
- What you do
- What, how, how often and who, so a deviation is found in time to hold the product. Continuous where possible.
- Sheet in this template
- HACCP plan
10. Establish corrective actions (principle 5)
- What you do
- Written in advance for each CCP: restore control, hold and decide on the affected product, find the cause, record it.
- Sheet in this template
- HACCP plan
11. Validate the plan, then verify it (principle 6)
- What you do
- Evidence before use that the plan can control the hazards, then record reviews, calibration, testing and audits by someone other than the person monitoring.
- Sheet in this template
- Verification
12. Documentation and records (principle 7)
- What you do
- Keep the plan, its scientific basis and the records it produces: monitoring, deviations, corrective actions and verification.
- Sheet in this template
- HACCP plan and every sheet
A filled-in example
Illustrative, not a benchmarkAn example: a made-up chilled sauce plant writes the plan for a tomato and cream pasta sauce, cooked in a kettle, cooled, filled into sealed 500 g tubs and sold chilled (illustrative; the two numeric limits are quoted from the published sources named, not validated for any real process).
The example's 13 process steps and its 3 CCPs
- 1Receive chilled cream
- 2Receive canned tomatoes, vegetables, herbs and dry goods
- 3Store: cream chilled, other goods ambient
- 4Peel and chop onion and garlic; open cans
- 5Weigh ingredients
- 6Sweat onion and garlic, add tomatoes and herbs, blend smooth
- 7CCP 1: Add cream and cookCritical limit: the sauce at its coldest point at 70°C (158°F) or above for at least 2 minutes
- 8CCP 2: Cool in the kettleCritical limit: from 57°C to 21°C within 2 hours and to 5°C within 6 hours
- 9Fill into tubs
- 10Seal lid film and print use-by date
- 11Apply label sleeve
- 12CCP 3: Metal detectionCritical limit: every tub passes a detector that rejects the site's test pieces, checked at start-up, every hour, after any stop and at the end of the run
- 13Chilled storage and dispatch
The chilled sauce flow, step by step, from receiving to dispatch. Step 7, cook, is CCP 1; step 8, cool, is CCP 2; step 12, metal detection, is CCP 3, each with its critical limit.
- 13 process steps, each walked on day and night shifts. The walk added the can opener, which was missing from the diagram.
- 18 hazards listed; 12 are significant on the example grid (severity x likelihood of 4 or more), and each of the 6 others has a written reason.
- Cook, CCP 1: the sauce at its coldest point at 70°C (158°F) or above for at least 2 minutes, the time FDA's draft preventive controls guidance gives for a 6-log reduction of Listeria monocytogenes (Appendix 3, Table 3-D).
- Cool, CCP 2: from 57°C to 21°C within 2 hours and to 5°C within 6 hours, the FDA Food Code 2022 cooling times (3-501.14), confirmed by cooling trials on full batches. Cooking does not kill the spores of C. perfringens and B. cereus, so the cook and the cool work as a pair.
- Metal detection, CCP 3: every tub passes a detector that rejects the site's test pieces, checked at start-up, every hour, after any stop and at the end of the run. The test-piece sizes come from the site's own validation.
- Listeria in the filling room, cashew cross-contact from a pesto on the same filler, the label sleeve check and the cold store answer Q1 Yes: prerequisite programmes that need monitoring and records, not CCPs.
3 CCPs, 12 significant hazards all with a control, 3 complete CCP rows and 0 hazard rows to fix. The plan summary still shows 1 item to fix: the thermometer calibration is 7 days overdue, and 2 more verification activities fall due within 14 days.
Common mistakes
Too many CCPs
Calling every check a CCP spreads attention thin and buries the steps that make the food safe. If a prerequisite programme controls a hazard, or a later step does, the decision tree says it is not a CCP here. Keep CCPs for the steps where control is essential.
Critical limits nobody can measure
"Cook thoroughly" or "metal detector working" is not a limit. Write a value the operator can read or see on the shift: a core temperature and a time, a pH, a detector that rejects named test pieces. Then keep the evidence that the value controls the hazard.
Monitoring too seldom to act on
A cooling log filled in once a shift cannot tell you which batches to hold. Monitor continuously where you can, and otherwise often enough to isolate every product a deviation could have affected.
Limits copied, never validated
A temperature from a guidance document is a starting point. Show it is reached at the coldest point of your own kettle, at your batch size, with your product, before the plan is used, and again after a change of equipment, recipe or process.
A flow diagram nobody walked
Diagrams drawn in the office miss rework loops, the night-shift shortcut and the step added last year. Walk the line on every shift and during cleaning; the hazards at the missing steps are the ones nobody controls.
Download the template
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
Run this template in LeanSuite
In LeanSuite, food and beverage plants build their own GMP inspections and HACCP verification checks in Lean Creator, complete them on a phone or tablet with photos, and turn failed items into corrective actions tracked to verified closure.
See it in a 45-minute demoIn the lean glossary
Free tools
Guides
- Lean playbook for food and beverage plants
- FMEA in Manufacturing: Failure Mode and Effects Analysis Complete Guide
- CAPA Systems in Manufacturing: Corrective and Preventive Action Explained
- How to Perform an Effective Root Cause Analysis in Manufacturing
- Mock recall template: traceability exercise worksheet
FAQ
HACCP plan template: hazard analysis and CCP worksheet: common questions
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- Standard work audit checklist24 checks of a job against its written standard, ten timed cycles, and each gap sorted by cause before anyone acts.
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- Standard work combination tableOne operator's manual, machine, walk and wait time on a time chart against takt, with machine cycles and a process capacity sheet.
- Lead time worksheetProduction lead time from the inventory waiting at each step, value-added time and process cycle efficiency, plus an order traced from order to delivery.
- Waste walk checklist (TIMWOODS)32 things to look for across the eight wastes, with where and how much, and a findings log with dot votes, owners and dates.
- Maintenance KPI trackerMTBF, MTTR, availability and PM compliance per asset and month, plant figures from the totals, planned maintenance % and backlog in weeks.
- Daily huddle agendaA 15-minute start-of-shift stand-up in six timed blocks, with yesterday's SQCDP results, today's plan, actions and escalations.
- DMAIC project charter templateThe Define-phase charter on one page: problem and goal, metrics, scope, team and phase dates, with savings and a tollgate checklist.
- Water spider route plan (mizusumashi)A water spider's fixed route: stops with arrival times, what is delivered and collected, route time against the cycle, cart load and a trip log.
- Cost deployment matrixCost deployment on paper and in Excel: loss quantities by process, causal and resultant losses, the cost of each loss, a Pareto and the projects that recover them.
- Equipment criticality analysisAssets scored 1 to 5 on six criteria with your own weights, ranked and sorted into classes A, B and C with a safety override and a suggested maintenance strategy.
- Bottleneck analysis worksheetEffective capacity per station from cycle time, parallel units, availability and yield, the bottleneck, takt and utilization, a queue cross-check and the five focusing steps.
- Fault tree analysis templateA drawing area with the FTA symbols, an event table with probabilities and minimal cut sets, and the gates worked out bottom-up in Excel.
- 5G investigation sheetConfirm the facts before naming a cause: 5W1H, the five G's with 20 prompts, the gap against the principle and the standard, and the countermeasures.
- Yokoten tracker (horizontal deployment)Copy a proven improvement line by line: the source result, each candidate's own before and after, its share of the source's improvement and the standard updated.
- Coaching kata template (improvement kata storyboard)The learner's storyboard (target condition, current condition, obstacles, PDCA cycles) and a fold-over card with the coach's five questions.
- SMART goals templateWrite a goal, test it against the five SMART letters, then track progress toward the target against the time used.
- Lean readiness assessment templateTwenty statements in four factors, scored 1 to 5 by several people on their own, with averages, the spread between them and the actions.
- Nemawashi template (stakeholder plan)Plan the one-to-one conversations before a decision: who to talk to in what order, their concerns, what changed and where they stand.
- Breakdown analysis reportOne equipment breakdown from the stop to the 90-day check, plus a breakdown log with repeat flags, MTBF and MTTR by asset and a Pareto of causes.
- Heijunka box planner (production leveling)Weekly demand turned into containers a day, takt, pitch and slots, a leveled sequence of products and the heijunka box, with a check that the changeovers fit.
- Future state value stream map worksheetThe eight future-state questions worked through in order: takt, pitch, flow, supermarkets, the pacemaker and the mix, with an EPEI check and current against future lead time.
- Value stream plan (VSM action plan)The future-state map cut into loops, each with an objective and a measurable goal, and its kaizen bursts turned into owned, dated projects on a 12-month timeline.
- Kaizen project plan (Gantt chart)One improvement project as a Gantt chart: tasks by phase with owners, predecessors and working days, a 16-week grid, milestones and a status from planned against actual % done.
- Escalation matrix templateWho is called for each type of issue and after how long, with severity rules, contacts and an escalation log.
- Visual management audit checklist29 checks of whether anyone can tell normal from abnormal at a glance, scored by group, with a trend and actions.
- Employee recognition program templateDesign a recognition program on one page, then run it: points per action, prizes, budget, a points ledger, a monthly leaderboard and a fairness check by team and shift.
- Lean transformation roadmapA plant-wide lean program on one sheet: six phases with exit criteria, six workstreams by quarter over 24 months, the model line, metrics with baseline and target, cadence and risks.
- Obeya room plannerPlan the walls, owners, cadence, agenda and rules of an obeya, then run the weekly review of KPIs, problems, actions and milestones.
- Paper forms inventory (paperless manufacturing worksheet)Every paper form, checklist and log in one list: hours a month, who acts on it, how long the paper waits, and which forms to move first.
- Continuous improvement software evaluation scorecardCompare CI software vendors: a must-have gate, eight weighted criteria scored 1 to 5, points out of 100 and a rank, with a demo script and reference questions.
- Lean principles assessment templateThe five lean principles as 25 things you can see on one value stream, answered yes, partly or no on a walk, with a score per principle, the next step and a trend over walks.
- Employee engagement survey templateA short anonymous pulse survey for shop floor staff: 14 statements in six drivers, two open questions, results by driver and team, and the actions.
- Hansei reflection sheet (lessons learned)A written look back at one finished project, event or launch: goals against results in numbers, causes rather than blame, lessons to keep or change, and where else they apply.
- Daily kaizen routine boardA team's 10 to 15 minute daily routine at the board: one problem from each person, small fixes with one owner, counted every week.
- Weekly maintenance schedule templateNext week's maintenance jobs, scheduled only when ready, loaded against each craft's hours by day, with schedule compliance and break-ins at week end.
- Operational excellence assessment templateThe ten principles of operational excellence as 30 behaviors and practices you can see, scored 1 to 5 by several people, with the spread, the three lowest principles and an action plan.
- Scrum meeting agenda templateTimed agendas for the five scrum meetings, a sprint planning sheet, a retrospective sheet, and an Excel sprint backlog with a burndown.
- Toyota Production System (TPS) house templateThe TPS house for one plant or value stream: roof, two pillars and foundation, with what you do today, the evidence, a status and the next step for each element.
- EPEI and batch size calculatorHow often each part can come round on a shared machine (EPEI) and how big each batch must be, from demand, cycle times and changeovers, now and after SMED.
- People, process, technology (PPT) assessmentCheck one change before go-live: 18 people, process and technology statements scored 1 to 4 by the people who will use it, the lowest element and the actions.
- Process capacity sheet templateEach machine in a part's routing with manual, auto and tool change time, its capacity per shift, and the step that limits the cell against demand.
- Team charter templateA one-page charter for a standing team: purpose, scope, roles, the KPIs it owns, which decisions it makes itself, norms and cadence.
- Chaku-chaku line plannerPlan a load-load cell: time each machine, load and walk, check that every machine is ready when the operator comes back, compare the cell cycle with takt and size the crew.
- Standard operating procedure (SOP) templateA full SOP in the hierarchical step format, from purpose and scope to the steps, records, revision history and approvals, with review checks and an SOP register.
- Process improvement method selectorEight questions about one problem, an example rule that suggests a method and a matrix of nine methods: when each fits, the usual team and time, and the template to start with.
- Autonomous maintenance 90-day model area planAM steps 0 to 3 on one model machine in 13 weeks, a KPI board, the day-90 gate and expansion waves for months 4 to 12.
- Professional maintenance (PM) 90-day model area planThirteen weeks from breakdown analysis to a running PM calendar on one model machine, a KPI board, the day-90 gate and expansion waves.
- Environment and energy pillar 90-day model area planThirteen weeks from waste and energy maps to area standards on one model area, a KPI board, the day-90 gate and expansion waves.
- Focused improvement 90-day model area planThirteen weeks from the loss Pareto to standardized fixes on one model line, a KPI board, the day-90 gate and expansion waves.
- Logistics and customer service pillar 90-day model area planThirteen weeks from the current-state map to pull on one model value stream, a KPI board, the day-90 gate and expansion waves.
- People development pillar 90-day model area planThirteen weeks from the skills matrix to trained cover on critical tasks in one model area, a KPI board, the day-90 gate and expansion waves.
- Early equipment management 90-day model area planThirteen weeks from lessons on current machines to a tracked start-up on one model equipment project, a KPI board, the day-90 gate and expansion waves.
- Cost deployment pillar 90-day model area planThirteen weeks from the loss map to costed, ranked projects in one model area, a KPI board, the day-90 gate and expansion waves.
- Moving from Excel to one system checklistA 34-point checklist and a file inventory for moving trackers from spreadsheets to one system: keep, move, connect or retire, clean, pilot, run both, retire.
- Prioritization matrix templateScore up to 20 improvement ideas on weighted criteria, rank them, test the ranking with equal weights and place each one on an effort and benefit grid.
- Cost per unit worksheet (manufacturing cost per good unit)One product's cost per good unit by materials, labor, machine and overhead, the gap to target, and which cost lever is worth most a year.
- Digital manufacturing readiness assessmentScore 24 statements on process, technology and people from 0 to 4, check the balance between them and rank the gaps by what matters in your plant.
- Manufacturing KPI dashboard templateWeekly plant numbers in, 14 KPIs out: OEE and its parts, first pass yield, scrap, on-time delivery, recordable rate, cost and absence, each against a target.
- RCM worksheet (failure mode and task selection)Failure modes classed as hidden, safety, operational or non-operational, then a task chosen for each: condition-based, discard, failure-finding, redesign or run to failure.
- Downtime reason codes template26 starter codes mapped to the six big losses, a log with drop-downs, a Pareto by code and by loss, and a code card for the line.
- Kaizen event preparation checklistEverything that has to be ready before a kaizen event and done after it: 44 items with owners and due dates from 6 weeks before day 1 to 30 days after, five go or no-go gates and a day-by-day agenda.
- Critical spare parts list and stocking levelsAssets ranked by consequence, each part classed and given a stocking policy, and min and max worked out from usage and lead time, with the downtime each stock-out would cost.
- Tier 2 meeting agenda and escalation sheetA 15-minute tier 2 agenda in ten timed blocks, fixed roles and rules, escalation triggers with time limits, and a log that ages every escalation and sends the answer back down.
- Plan for every part (PFEP) templateOne row per part: supplier, pack, container, usage, lead time and locations, with ABC classes, market and line kanban counts and a lineside space check.
- Changeover matrix templateA from-to matrix of changeover minutes with the clean each transition needs (allergen, colour, format), and a weekly planner that totals the order and suggests a shorter one.
- Maintenance job plan templateOne job planned on one sheet: steps and craft hours, parts checked against stock, tools, lockout and permits, documents, a ready check for the schedule, and technician feedback.
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A shift handover sheet, a red tag log, a changeover checklist for one machine: if your team uses it on the floor, ask.