Last Updated on December 2, 2025 by Melissa Lazaro

Why a Hazard Analysis Worksheet Makes Life Easier

If there’s one HACCP step that makes people pause, it’s hazard analysis. I’ve seen teams breeze through prerequisites and flow diagrams… then freeze when it’s time to decide which hazards matter, how to assess risks, and whether a step should be a CCP.

That hesitation is normal.

Hazard analysis requires judgment. And judgment needs structure — not guesswork.

A well-built hazard-analysis worksheet takes the pressure off. It helps you think systematically, justify decisions, and avoid the kind of gaps auditors love to flag.

By the time you finish this guide, you’ll know exactly how to fill out the worksheet step by step, avoid the usual mistakes, and use it as real evidence of due diligence — not just paperwork.

Break Down the Process Flow (Process Mapping for Hazard Analysis)

Before assessing anything, you need a clear picture of how the product actually moves through your facility.

Here’s what usually works best:

1. Start with your process flow diagram.
2. List each step in the exact order product moves.
3. Verify that flow by walking the floor — not just relying on memory.

It sounds simple, but I’ve seen hazard analysis collapse because a single step was missing — usually cooling, rework, or temporary holding.

Pro Tip:
Never finalize your worksheet until production staff review it. People closest to the work spot missing steps faster than any consultant or auditor.

Common Mistake:
Only listing “major” steps like receiving or cooking. Every step counts — even if the hazard seems minimal.

A client once skipped “temporary storage during shift change,” and later discovered a condensation-related microbial risk. One missing line changed their whole plan.

Identify Hazards for Each Step (Biological, Chemical, Physical Hazards)

Once the steps are listed, the next question is:
What could go wrong here?

To keep it simple, focus on three categories:

• Biological hazards (Salmonella, Listeria, E. coli, yeast, mold)
• Chemical hazards (allergens, chemical residues, cleaning agents)
• Physical hazards (metal fragments, glass, plastic, bone)

Don’t rush this part. It’s tempting to write “no hazard exists”, but unless you can defend that statement, it will raise eyebrows during an audit.

Good sources of hazard insight include:

• Regulatory lists
• Supplier specifications
• Past recalls or complaints
• Industry guidance
• Internal incident history

Pro Tip:
Always consider allergen cross-contact — even if you think your process is allergen-free.

Common Mistake:
Only listing hazards that have already happened. HACCP is proactive, not reactive.

Risk Assessment: Severity + Likelihood (Risk Matrix for HACCP)

Here’s where things get more analytical. It’s not enough to list hazards — you also need to evaluate how serious and how likely they are.

A simple scoring method usually works best:

Scale	Severity	Likelihood
1	Negligible	Rare
3	Moderate	Possible
5	Severe	Likely

Multiply the two numbers to calculate a risk score.

Example:

Metal contamination during slicing:
Severity: 5 (serious injury risk)
Likelihood: 2 (rare under current controls)
Risk Score: 10

That number drives your decision-making at the next stage.

Pro Tip:
Keep your scoring definitions written and consistent — don’t guess differently each time.

Common Mistake:
Scoring everything high to “play it safe.” In reality, this usually creates unnecessary CCPs and complicates your entire system.

Determine Control Measures (Preventive Controls vs CCP)

Once the risk is clear, decide how the hazard is controlled. Sometimes the control already exists — for example, supplier guarantees, sanitation programs, or metal detection.

You’re not jumping to CCPs yet — you’re evaluating whether existing measures are enough.

Ask:

• Is there already a reliable control in place?
• Is the control preventive or corrective?
• Is the control measurable and enforceable?

Sometimes a prerequisite program (PRP) is enough — sometimes it isn’t.

Pro Tip:
Document your reasoning even if the decision is “no CCP needed.” Auditors care more about justification than assumptions.

Common Mistake:
Treating every serious hazard as a CCP without considering whether it’s controlled earlier in the process.

Decide if the Step Is a CCP (Decision Tree for HACCP)

Now you narrow things down.

A decision tree helps you determine whether the hazard at a step requires critical control — not just monitoring.

A simplified logic flow works well:

1. Is the hazard significant?
2. Is control necessary at this step?
3. Can the hazard be controlled later?
4. If not controlled — would the product be unsafe?

If you answer yes to the right places, the result may be a CCP.

Pro Tip:
Record your decision tree answers in full sentences — not just checkmarks. Clear logic protects you during audits.

Common Mistake:
Using the decision tree mechanically without real reasoning — that leads to inconsistencies.

I’ve seen teams mark a metal detector as “not a CCP” simply because they misunderstood the logic. Clear documentation prevents that.

Verify, Review & Approve (Internal Review & Audit)

Before finalizing, review the worksheet with fresh eyes — ideally someone who wasn’t the main author.

Your final review should confirm:

• All process steps are included
• Risk scoring is consistent
• Controls match reality — not theory
• Decisions are justified and traceable
• CCPs are clear, necessary, and defendable

A short internal audit at this stage saves a long corrective action later.

Pro Tip:
Schedule hazard analysis reviews annually — and whenever there’s a change in product, equipment, supplier, or regulation.

FAQs

How often should hazard analysis be updated?
At least annually — or sooner if there’s a major process change.

Can one worksheet be used for multiple products?
Yes — if the products share similar hazards and processing steps.

Do auditors expect risk scoring?
Yes. Even if not required, risk scoring makes your reasoning stronger and more defensible.

Conclusion — Download and Put It Into Action

A hazard-analysis worksheet isn’t just a form — it’s the backbone of your HACCP plan. When it’s done well, everything that follows becomes easier: CCPs, monitoring plans, validation, verification, and audits.

If you’re ready to move from understanding to action, the next step is simple:

Download the editable HACCP Hazard-Analysis Worksheet and start building your analysis step by step.