Our recent poll was clear: the majority response was “No—hands-on is required.”
We agree. An auditor may understand standards, interpret flowcharts, and master checklists, but to be truly effective in identifying real risks, influencing behaviors, and strengthening the system, factory time is a force multiplier that can’t be replaced.
Books, procedures, and checklists specify what should happen, but the factory floor reveals what occurs through subtle cues: the smell after CIP, uneven pump sounds, or the awkward pause before someone admits a workaround. These details often don’t appear in documents, but they define the reality of quality and food safety.
Factory experience enhances auditors’ ability to rapidly grasp the environment. A factory-fluent auditor instinctively perceives process flow, detects bottlenecks, and notices workarounds. They differentiate normal variability from genuine risks. They recognize why a wet corner after sanitation is problematic or how a valve’s position influences cross-contamination. Such insights go beyond checklists; they stem from exposure to the noise, steam, and pressure of production.
Hands-on experience builds credibility, as operators and supervisors recognize those who have worn factory boots. This shifts the conversation, as people open when they sense an auditor understands their world. They share honest truths, trusting the information will be used to improve, not punish.
Factory fluency isn’t about years of experience but about understanding how a facility creates value and manages risk. It involves understanding how materials flow, the limitations of staffing and changeovers, and potential weak spots in utilities or sanitation. It also includes recognizing human factors, such as fatigue, the pressure to keep lines running, and unspoken norms that influence decisions.
A true auditor’s skill is being able to explain how a process works and where it can fail. Without this, audits become dry, focused on documents, and lacking insight. Inexperienced auditors may concentrate on verifiable paperwork, missing real vulnerabilities, which damages credibility.
Not all auditors need years; a few weeks or months in production can be transformative. Hands-on tasks, from pre-op checks to sanitation, teach lessons no classroom can. Shadowing technicians or tracing deviations reveals the operation logic better than SOPs. Even brief experiences help understand process maps, identify risks, and challenge controls.
An auditor without factory experience can be compliant and capable but never fully effective. True effectiveness depends on factory fluency, the practical understanding that transforms data into judgment and findings into action. It builds trust, improves insight, and keeps assurance grounded.
Auditing is an apprenticeship, learned through experience. The more auditors understand factory operations, the better they can help develop safer products, stronger systems, and lasting trust.
By Marc Cwikowski
October 08, 2025
