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Training content
Overview
BRCGS Hazard and Risk Analysis (HARA) Training is designed to provide the knowledge and practical skills required to systematically identify potential hazards relating to product safety, quality and legal compliance, assess risks and establish appropriate control measures.
The language of the training is Turkish. The training is delivered online. The training provider is BRCGS.
About the Training
The training covers the fundamental principles of the HARA approach, prerequisite programmes, formation of the HARA team, product and process descriptions, process flow diagrams, hazard identification, likelihood and severity assessment, control measures, critical control points, critical limits, monitoring, corrective actions, validation, verification and review of the HARA plan.
Who Should Attend?
- Technical managers and technical personnel
- Quality managers and quality personnel
- Product safety team members
- Production and operations personnel
- Engineering personnel
- New product development personnel
- Internal auditors
- BRCGS auditors
- Personnel involved in developing and implementing HARA plans
Objectives and Outcomes
The aim is to enable participants to correctly understand the principles of hazard analysis and risk assessment, develop a systematic HARA plan, identify significant risks relating to product safety, quality and legal compliance, and establish and implement appropriate control measures.
By the End of the Training
Participants will be able to:
- Explain the purpose and fundamental principles of the HARA approach.
- Distinguish between the concepts of hazard and risk.
- Establish the HARA team and define the scope of its work.
- Evaluate the role of prerequisite programmes.
- Identify hazards arising from products and processes.
- Conduct risk assessments using likelihood and severity criteria.
- Identify appropriate control measures.
- Establish critical control points and control criteria.
- Plan monitoring, corrective action, validation and verification activities.
- Develop and review a structured HARA plan.
Programme and Method
Overview of HARA
- The concept of HARA
- Hazard analysis and risk assessment
- The purpose of the HARA system
- The relationship between product safety, quality and legal compliance
- The HARA approach in BRCGS standards
- Benefits of a structured HARA plan
The Relationship Between HARA and HACCP
- Overview of the HACCP approach
- Similarities between HARA and HACCP
- Scope of HARA
- Product safety risks
- Quality risks
- Legal compliance risks
Establishing the HARA Team
- Multidisciplinary team approach
- Appointment of the team leader
- Competence of team members
- Technical knowledge and experience
- Definition of roles and responsibilities
- External expert support where necessary
Prerequisite Programmes
- The purpose of prerequisite programmes
- Site and infrastructure conditions
- Cleaning and hygiene
- Maintenance
- Pest control
- Personnel practices
- Storage and dispatch
- Supplier controls
Scope of the HARA Study
- Identification of product groups
- Definition of processes
- Boundaries of the HARA study
- Activities included
- Identification of product safety, quality and legal requirements
Preparing the Product Description
- Product characteristics
- Raw materials and ingredients
- Packaging
- Storage conditions
- Distribution conditions
- Intended use
- User or consumer groups
Process Flow Diagram
- Identification of process steps
- Raw material and material inputs
- Processing stages
- Rework
- Storage
- Dispatch
- Documentation of the flow diagram
Verification of the Flow Diagram
- On-site verification of the flow diagram
- Comparison with the actual process
- Assessment of different shifts
- Consideration of process changes
- Updating the flow diagram
Hazard Identification
- Product safety hazards
- Physical hazards
- Chemical hazards
- Microbiological hazards
- Quality risks
- Legal compliance risks
- Risks arising from raw materials and processes
Risk Assessment
- Assessment of likelihood
- Assessment of severity
- Risk scoring methods
- Risk matrices
- Acceptable risk levels
- Identification of significant hazards
- Justification of the risk assessment
Identification of Control Measures
- Existing control measures
- Preventive controls
- Detective controls
- Process controls
- Identification of the need for additional controls
- Assessment of the effectiveness of control measures
Identification of Critical Control Points
- The concept of a critical control point
- Identification of critical control points
- Decision-making approach
- Justification of control points
- Differentiation between critical and other control points
Establishing Critical Limits
- The purpose of critical limits
- Measurable criteria
- Legal requirements
- Technical and scientific information
- Acceptance criteria
- Validation of critical limits
Establishing Monitoring Systems
- Monitoring methods
- Monitoring frequency
- Assignment of responsibilities
- Measurement and observation methods
- Creation of records
- Timely detection of deviations
Corrective Actions
- Identification of loss of control
- Control of the affected product or process
- Correction
- Root cause analysis
- Corrective action
- Prevention of recurrence
- Recording of actions
Validation
- Validation of control measures
- Validation of critical limits
- Assessment of technical and scientific evidence
- Test and study results
- Validation records
Verification
- Verification of the HARA plan
- Review of monitoring records
- Internal audits
- Sampling and analysis results
- Assessment of the effectiveness of control activities
- Verification of critical control points
Documentation of the HARA Plan
- Product description
- Flow diagram
- Hazard analysis
- Risk assessment
- Control measures
- Critical limits
- Monitoring records
- Corrective action records
- Verification and validation records
Review of the HARA Plan
- Periodic review
- New products
- New raw materials
- Process changes
- Equipment changes
- New hazards
- Changes in legal and customer requirements
- Assessment of non-conformities and incidents
HARA in BRCGS Standards
- Consumer Products applications
- Packaging Materials applications
- Storage & Distribution applications
- Agents & Brokers applications
- Assessment of standard-specific risks
- Adaptation of the HARA plan to the relevant standard
Common Errors in the HARA System
- Incomplete hazard identification
- Inappropriate risk criteria
- Inadequate risk justification
- Incorrect identification of control measures
- Incorrect selection of critical control points
- Inadequate verification and validation
- Outdated HARA plans
Case Studies
- Product and process definition
- Preparation of a flow diagram
- Hazard identification
- Risk assessment exercise
- Identification of control measures
- Assessment of critical control points
- Preparation of a sample HARA plan
Training Method
The training is delivered through subject presentations, assessment of BRCGS requirements, case studies, hazard identification and risk assessment exercises, flow diagram exercises and the preparation of sample HARA plans.
Attendance and Certificate
Certificate Rules
A certificate of attendance is issued to all participants whose attendance has been confirmed. To receive a certificate of achievement, participants must achieve a passing grade in the examination at the end of the training; participants who use all their examination attempts but do not pass will be issued a certificate of attendance.
FAQ and Resources
Who is the BRCGS Hazard Analysis and Risk Assessment (HARA) Training suitable for?
It is intended for technical and quality managers involved in the development and implementation of HARA plans, production, engineering and new product development personnel, product safety team members and auditors.
What is the main objective of the training?
The main objective is to enable participants to apply the principles of hazard analysis and risk assessment correctly and develop a structured HARA plan that controls product safety, quality and legal compliance risks.
What is the difference between HARA and HACCP?
While HACCP focuses primarily on controlling food safety hazards, the HARA approach may also include the systematic assessment of quality and legal compliance risks alongside product safety, depending on the relevant BRCGS standards.
Does the training include practical exercises?
Yes. The training uses case studies and practical exercises covering hazard identification, risk assessment, flow diagram development, assessment of critical control points and preparation of a sample HARA plan.
Is there an examination at the end of the training?
Yes. An assessment examination is administered at the end of the training.
References
- BRCGS Hazard Analysis and Risk Assessment (HARA) Course Materials
- BRCGS Global Standards
- BRCGS Product Safety Management Guidance
- BRCGS Consumer Products Standard
- BRCGS Packaging Materials Standard
- BRCGS Storage and Distribution Standard
- BRCGS Agents and Brokers Standard
- Relevant BRCGS guidance and guidelines