Hazard Analysis and Critical Control Point (HACCP) and OPRP Identification in ISO Occupational Health and Safety Management

In today’s fast-paced industrial environment, ensuring the health and safety of employees is not just a legal requirement it’s a moral and strategic responsibility. One of the key approaches to achieving this is through systematic Hazard Analysis and Critical Control Point (HACCP) processes and the identification of Operational Prerequisite Programs (OPRPs) within the framework of ISO Occupational Health and Safety Management Systems (OHSMS), particularly under ISO 45001:2018.

This article explores how HACCP principles integrate with OHS management and how identifying OPRPs strengthens workplace safety performance.

  1. Understanding Hazard Analysis and Critical Control Point (HACCP)

Originally developed for the food industry, the HACCP system is a proactive, preventive approach to identifying and controlling hazards that could compromise safety. The same methodology can be applied beyond food production—into industrial, manufacturing, and service environments—to manage occupational health and safety risks.

HACCP involves:

  1. Identifying hazards – recognizing biological, chemical, and physical hazards that could harm workers.
  2. Determining critical control points (CCPs) – identifying points in a process where controls can be applied to prevent or reduce risks to an acceptable level.
  3. Establishing limits, monitoring, and corrective actions – defining what safe conditions look like and ensuring immediate action is taken when deviations occur.
  1. HACCP in the Context of ISO 45001:2018

ISO 45001:2018, the international standard for Occupational Health and Safety Management Systems (OHSMS), emphasizes a risk-based approach similar to HACCP. While HACCP focuses on process safety, ISO 45001 extends this to include human factors, leadership, worker participation, and continual improvement.

Integrating HACCP principles within an ISO 45001 framework helps organizations:

  • Identify potential hazards at each process stage
  • Establish proactive controls to minimize workplace risks
  • Align operational safety controls with strategic risk management
  • Demonstrate compliance with legal and ISO requirements
  1. What Are Operational Prerequisite Programs (OPRPs)?

Within the broader risk management framework of ISO standards particularly ISO 22000 (Food Safety Management) and ISO 45001 (Occupational Health & Safety)—OPRPs (Operational Prerequisite Programs) serve as the bridge between general prerequisites (PRPs) and critical control points (CCPs).

Definition:
An OPRP is a control measure applied to reduce the likelihood of a hazard occurring, but not as stringent as a CCP. It ensures that operational conditions remain safe and under control.

In an OHS management system, OPRPs may include:

  • Routine maintenance of machinery and safety devices
  • Worker training and competency programs
  • Safe operating procedures (SOPs) for hazardous tasks
  • Access control to high-risk zones
  • Equipment calibration and inspection schedules

These measures do not necessarily eliminate a hazard but ensure consistent control and reduce the probability of incidents.

  1. Integrating OPRP Identification into Hazard Analysis

The process of identifying OPRPs begins with comprehensive hazard analysis, a cornerstone of both HACCP and ISO 45001. The steps typically include:

  1. Mapping Processes: Outline all operational steps, inputs, and outputs.
  2. Identifying Hazards: Determine potential physical, chemical, ergonomic, or psychosocial hazards.
  3. Evaluating Risk: Assess each hazard’s likelihood and potential impact.
  4. Determining Control Measures: Decide which hazards require CCPs and which can be managed through OPRPs.
  5. Documentation and Monitoring: Maintain evidence of risk assessments, decisions, and control implementations.

Through this approach, organizations create a structured risk control matrix that prioritizes prevention and ensures continual compliance.

  1. Benefits of Integrating HACCP and OPRP in OHSMS

Implementing HACCP and OPRP identification within an ISO 45001 framework provides numerous benefits:

  • Improved workplace safety culture through proactive risk management
  • Reduced incidents and near misses by controlling risks at the source
  • Better compliance with national and international safety standards
  • Enhanced employee confidence and participation
  • Streamlined audits and certification readiness

Ultimately, this integration transforms safety from a reactive compliance exercise into a strategic performance enabler.

  1. Conclusion

Adopting Hazard Analysis and Critical Control Point (HACCP) methodology alongside Operational Prerequisite Program (OPRP) identification ensures a robust, preventive occupational health and safety system. When effectively aligned with ISO 45001, these tools empower organizations to predict, prevent, and manage risks before they escalate building safer workplaces and stronger reputations.

Investing in hazard-based safety management is not merely about compliance; it’s about cultivating a culture of care, responsibility, and continuous improvement.