HACCP — Critical Control Points

What is a CCP?

A Critical Control Point (CCP) is a step in your production process where control is essential to prevent a food safety hazard. Examples:

Create a CCP

From the Dashboard

1. Go to Food Safety -> HACCP
2. Click New CCP
3. Configure:
   • Name: Descriptive name (e.g., "Oven Zone 3 Temperature")
   • Equipment: Select the asset that monitors this CCP
   • Data source: Select the event source that sends readings
   • Metric: The field in the event data (e.g., "temperature")
   • Hazard type: Biological, Chemical, or Physical
   • Upper limit: Maximum acceptable value
   • Lower limit: Minimum acceptable value
   • Unit: degrees C, degrees F, bar, pH, etc.
   • Grace period: Seconds allowed out of limit before requiring action
   • Predefined corrective actions: List of steps to follow if there is a deviation
   • Responsible person: Who must act

From the API

POST /api/v1/haccp/ccps
{
  "name": "Oven Zone 3 Temperature",
  "asset_id": "asset_abc123",
  "source_id": "source_plc_oven",
  "monitoring_metric": "temperature",
  "hazard_type": "biological",
  "parameter_type": "temperature",
  "critical_limit_high": 180,
  "critical_limit_low": 165,
  "unit": "C",
  "grace_period_seconds": 60,
  "corrective_actions": [
    "Stop production",
    "Verify sensor calibration",
    "Inspect product in affected zone",
    "Document and notify supervisor"
  ],
  "responsible_person_id": "person_tech01"
}

Automatic Monitoring

Once configured, Rela evaluates each sensor reading against the CCP limits:

• Reading within limits — Status: Under control
• Reading out of limits, within grace period — Status: Deviation detected
• Reading out of limits, grace period expired — Status: Corrective action required

Deviations are automatically recorded with:

• Reading value
• Deviation from limit
• Duration
• Direction (above / below)

HACCP Dashboard

The dashboard shows:

• Summary bar: "5 of 5 CCPs under control" or "2 require corrective action"
• Cards per CCP: Current reading, limits, time in deviation, corrective action button
• History: List of deviations with dates and actions taken

Pipeline Integration

CCPs are evaluated within the existing event pipeline:

1. Event arrives via MQTT/OPC UA/Modbus -> machine_webhook_service
2. After logging the event -> haccp_service.check_ccp_reading()
3. If there is a deviation -> it is recorded + WhatsApp/email notification
4. If corrective action is required -> automatic task + audit trail entry
5. In parallel -> statistical anomaly detection continues running

CCPs do not replace anomaly detection — they complement it. Anomalies detect statistical changes; CCPs verify regulatory compliance.