Top FSSC 22000 V6 Audit Non‑Conformities
Learn from Real Audit Findings, Not the Hard Way
At QSE Academy, we’ve reviewed hundreds of FSSC 22000 audit reports from clients across food manufacturing, packaging, and logistics. And you know what stands out every time?
The same non-conformities keep showing up — regardless of the company’s size or experience.
Most organizations don’t fail because their systems are broken. They fail because small gaps go unnoticed until the auditor points them out.
This article breaks down the most common non-conformities under FSSC 22000 V6, explains why they happen, and shows you how to prevent them before they cost you time, money, or your certificate.
Understanding FSSC 22000 V6 Non-Conformities
Let’s start with the basics — not all findings are equal.
During an audit, your certification body classifies non-conformities into three levels:
- Major: A system breakdown or serious food-safety risk.
- Minor: A small lapse that doesn’t directly affect product safety.
- Observation: A potential weakness or improvement opportunity.
Treat observations as friendly warnings. Close them early, and you’ll avoid bigger issues in the next audit.
Example:
One of our clients ignored a “minor” observation about missing allergen-cleaning records. A year later, it turned into a major non-conformity during their surveillance audit.
Pro Tip:
Keep a running list of observations — they often predict your next audit findings.
Top FSSC 22000 V6 Non-Conformities (and How to Fix Them)
Here’s what auditors are most likely to flag — grouped by focus area.
a. Management Commitment & Food-Safety Policy
When leadership treats the FSMS as a side project, it shows immediately.
Typical Findings:
- Food-safety policy not communicated to employees.
- Management reviews skipped or poorly documented.
- Objectives not measurable or followed up.
- Food-safety culture not demonstrated.
How to Fix It:
Hold quarterly management reviews.
Set measurable objectives (e.g., “Zero customer complaints related to contamination”).
And make food safety visible — talk about it in meetings, post results on notice boards, celebrate improvements.
Pro Tip:
Ask random employees if they know your food-safety policy. Their answers reveal how well management commitment is working.
b. HACCP & Hazard-Analysis Weaknesses
Your HACCP plan is the heart of your FSMS — but it’s also where auditors find the most issues.
Typical Findings:
- Hazard analysis outdated or missing justifications.
- CCPs and OPRPs not validated or monitored properly.
- Incorrect flow diagrams.
How to Fix It:
Re-validate your HACCP plan yearly or whenever there’s a change in process, product, or raw material.
Keep evidence of validation — scientific data, testing, or expert review.
Train your HACCP team on FSSC 22000 V6 updates.
Example:
A frozen-food manufacturer we coached reduced HACCP findings by 90% just by reviewing flow diagrams and validation records quarterly.
c. PRP Implementation Gaps
Auditors spend a lot of time verifying Pre-Requisite Programs (PRPs) on site. That’s where hygiene, maintenance, and sanitation failures show up.
Typical Findings:
- Incomplete sanitation or pest-control logs.
- Uncalibrated thermometers or scales.
- Maintenance records missing.
How to Fix It:
Use a PRP monitoring checklist linked to ISO/TS 22002 requirements.
Make daily verification a routine task for supervisors.
And record verification signatures — auditors notice them.
Common Mistake:
Cleaning done well but not documented. Remember: if it’s not recorded, it didn’t happen.
d. Allergen, Food-Fraud, and Food-Defense Controls
These are newer hot-buttons under FSSC 22000 V6. Auditors are focusing hard on them.
Typical Findings:
- Allergen zones not clearly identified.
- No documented food-fraud or food-defense risk assessment.
- Mitigation actions not verified.
How to Fix It:
Update vulnerability and threat assessments annually.
Include supplier fraud-risk evaluation in your approval process.
Run allergen-cleaning validation tests regularly.
Pro Tip:
Hold a short “food-fraud refresher” meeting for your procurement and QA teams before the audit. It reminds them how their work fits the requirement.
e. Internal-Audit & Corrective-Action Deficiencies
Your internal audits and CAPA (Corrective and Preventive Action) system are your early-warning tools. When they’re weak, auditors know your system isn’t self-correcting.
Typical Findings:
- Internal audits not covering all clauses.
- Repeat findings without root-cause analysis.
- Actions closed without evidence.
How to Fix It:
Create a Corrective-Action Log with columns for root cause, assigned person, due date, and verification.
Always include objective evidence before marking an action “closed.”
During management review, discuss audit-finding trends — not just completion rates.
Pro Tip:
When an auditor asks, “How do you ensure effectiveness?” show them a trend graph of repeat findings. It’s simple, visual, and powerful.
f. Traceability & Recall Weaknesses
Traceability is tested live — it’s one of the most telling moments in a Stage 2 audit.
Typical Findings:
- Mock recalls not performed or documented.
- Missing supplier batch records.
- Inconsistent product coding.
How to Fix It:
Perform a full mock recall at least once a year.
Track how long it takes to trace forward and backward.
Keep recall reports signed by participants.
Example:
One of our clients clocked a 45-minute trace-back time before improvements. After process tightening, they hit 10 minutes flat — impressing their auditor.
g. Documentation & Record-Control Errors
Even great systems lose credibility when paperwork is messy.
Typical Findings:
- Outdated procedures still in use.
- Missing signatures or revision numbers.
- SOPs not matching actual practice.
How to Fix It:
Implement an electronic document-control system or a version-tracking matrix.
Train staff to access only current versions.
Archive obsolete documents properly — don’t delete them without traceability.
Root Causes Behind Repeated Non-Conformities
Most findings aren’t technical — they’re cultural.
Systemic Causes: weak internal audits, lack of follow-up, poor communication.
Behavioral Causes: high staff turnover, rushed training, or “audit panic mode.”
Pro Tip:
Every six months, run a trend analysis of all your audit findings.
Look for patterns — repeated departments, processes, or clauses.
Once you see the trend, you can fix the root problem instead of chasing symptoms.
Building a Culture That Prevents Non-Conformities
Prevention isn’t paperwork — it’s mindset.
When food safety becomes everyone’s job, non-conformities start disappearing naturally.
Simple Ways to Build Culture:
- Integrate food safety into daily briefings.
- Involve all departments — not just QA.
- Encourage employees to report issues early without blame.
- Hold monthly “food-safety walks” with leadership present.
Example:
A packaging facility we worked with started 10-minute morning “food-safety huddles.” Within six months, their minor findings dropped by 70%.
Corrective-Action Best Practices (Close Findings the Smart Way)
When a finding happens, how you close it matters more than how fast you close it.
Do This Instead:
- Identify the root cause. Ask “why” five times if needed.
- Assign ownership. One person per action — no “shared” responsibility.
- Set deadlines and track completion.
- Verify effectiveness. Check the process again in a month.
Keep evidence files for every corrective action — updated records, photos, or revised SOPs.
Pro Tip:
Never say “training completed” as your only corrective action. Auditors want proof that behavior changed, not just that people sat in a session.
FAQs — Understanding and Managing Audit Findings
Q1. What’s the difference between a major and minor non-conformity?
A major is a serious system failure affecting food safety; a minor is an isolated issue with low risk.
Q2. How long do we have to close findings?
Usually 28 to 90 days, depending on your certification body and severity.
Q3. Can we still get certified with minor findings?
Yes. As long as your corrective actions are accepted and verified on time.
Conclusion — Turn Findings into Strength
Non-conformities aren’t failures — they’re feedback.
Each one tells you where your system can grow stronger.
When you build awareness, accountability, and a culture of improvement, your next audit won’t feel like a test — it’ll feel like validation.
At QSE Academy, we help organizations understand and eliminate audit findings with ready-to-use templates, training, and expert coaching.
If you want to stay one step ahead, download our FSSC 22000 V6 Non-Conformity Log Template or book a session to analyze your audit trends with our team.
Let’s turn your next audit report into proof of excellence
Melissa Lavaro is a seasoned ISO consultant and an enthusiastic advocate for quality management standards. With a rich experience in conducting audits and providing consultancy services, Melissa specializes in helping organizations implement and adapt to ISO standards. Her passion for quality management is evident in her hands-on approach and deep understanding of the regulatory frameworks. Melissa’s expertise and energetic commitment make her a sought-after consultant, dedicated to elevating organizational compliance and performance through practical, insightful guidance.
