You have probably noticed that unannounced audits are becoming increasingly common across the manufacturing and processing industries. Whether it’s for SQF, BRCGS, FSSC 22000, or other GFSI-benchmarked certifications, surprise audits are designed to ensure that facilities maintain compliance year-round — not just during scheduled visits.

If an auditor walked into your facility today, would you be confident in passing? If the answer is anything less than an enthusiastic “yes,” it’s time to take proactive steps to strengthen your audit readiness.

Why Are Unannounced Audits Happening More Often?

Unannounced audits were introduced to combat “audit fatigue” and to discourage facilities from only preparing when they know an audit is coming. These inspections:

• Validate real-world compliance rather than “staged” scenarios
• Encourage a culture of continuous improvement
• Reduce food safety risks by keeping employees accountable every day

In fact, some schemes now require unannounced audits as part of their certification process. This means you need to be audit-ready 365 days a year, not just during your audit window.

Common Areas That Lead to Audit Non-Conformance

If an audit catches you off guard, it’s often because of overlooked day-to-day practices. Some of the most common non-conformance findings include:

• Incomplete or outdated documentation (e.g., SOPs, training records)
• Poor employee practices (handwashing, PPE compliance, hygiene)
• Gaps in training comprehension — employees know what to do during training but forget on the floor
• Improper corrective action documentation
• Housekeeping and sanitation issues

Any one of these can result in a major finding, putting your certification (and reputation) at risk.

Steps to Improve Your Audit Readiness

1. Maintain Accurate Documentation at All Times

Auditors will expect instant access to your records. That means training logs, policies, corrective actions, and monitoring records should be current and organized. Use digital tools whenever possible to avoid scrambling for paperwork.

2. Validate Employee Training and Competency

Training completion is not the same as comprehension. During an audit, employees may be asked to demonstrate procedures or answer questions. If they hesitate or guess, it signals weak compliance. Reinforce training with:

• On-the-job observations
• Knowledge checks
• Regular refresher sessions

3. Conduct Internal Mock Audits

Perform routine internal audits to simulate an unannounced visit. This practice reveals weaknesses before an actual auditor does and helps employees get comfortable answering questions under pressure.

4. Create a Culture of Continuous Readiness

Audit readiness shouldn’t be a last-minute scramble. Build a mindset of everyday compliance by:

• Recognizing employees who follow protocols
• Posting reminders for critical practices
• Empowering supervisors to coach in real time

The Bottom Line: Audit Readiness is Year-Round

Unannounced audits are here to stay. Facilities that prioritize everyday compliance, proper documentation, and strong employee training will be best positioned to succeed — not just to pass an audit but build trust with customers.

How the Alchemy Training System Helps You Stay Ready

The Alchemy Training System simplifies and strengthens your audit readiness strategy by:

• Centralizing training records for instant access during audits
• Offering customizable training programs to fit your facility’s exact requirements
• Providing knowledge checks and observations to validate comprehension
• Ensuring employees are consistently aligned with safety and quality standards

With the Alchemy Training System, you can turn “audit anxiety” into audit confidence — no matter when the auditor shows up.