AGROSAW - Monthly Safety Audit

AUDIT AREA

Check the list of nominated issuers, receivers, authorisers in the department (for PTW). The list shall be authorized by PLANT HEAD.

Interview one of the signing authorities for a ongoing PTW to check his understanding of the hazards & precautions, procedure to perform the job.

Check whether the DSR has conducted work in progress inspection on the Hot & Height work permits and initialled.

Check whether the SAFETY OFFICER has conducted work in progress inspection on the Hot & Height work permits and initiated.

PTW areas shall be barricaded with caution tapes and WIP boards.

Only fit for purpose facilities (ladder, safety harness, scaffolds, helmets etc) shall be used for permits. Check a ongoing permit whether the facilities are numbered and only fit for purpose is used.

LOTO shall be used for maintenance works. Check the compliance in an ongoing PTW.

Check the facilities available for performing LOTO.

Check the knowledge of LOTOTO within the team.

LOTO referance shall be included in the PTW sheet. Check for compliance.

Check whether list of authorised people, danger signage, LOTO information, PPE matrix are displayed in the entrance of panel room with contact details.

Check whether all eletrical panels has adequate illumination (Emergency lights shall also be provided for key panels)

Check whether appropriate clearance without any obstruction from all sides of the key panels and rubber mates as per IS standards

Check whether earthpits are tracable

Check whether earthpits are periodically tested (quarterly) & the test details are displayed near the earthpits.

Double earthing shall be available for electrical equipments ( ie motors etc ) & panels. Check compliance.

List of portable electrical cords shall be available and shall be complied.

Quarterly portable electrical cords inspections shall be conducted and only fit for purpose to be deployed in the plant.

List of portable electrical TOOLS shall be available and shall be complied.

Quarterly portable electrical TOOLS inspections shall be conducted and only fit for purpose to be deployed in the plant.

No visible damage to any electrical switches, panels or cables. Check compliance.

Conduct interviews and check awareness on the fire prevention and protection system.

At least one fire fighter shall be available in each area in each shift to support in case of any fire. Check compliance and system to ensure compliance.

Fire fighting team shall be identified with badges or any means. Check compliance.

Display fire fighters present in the shift in the department & plant. Check compliance.

Smoking shall not be permitted in the production area. No smoking signages, employee communications shall be done. Check compliance.

Emergency hooter shall be audible across the plant. Interview and check compliance.

Check for availability of list of chemicals, state, storage quantity & storage location.

Check for availability of MSDS for each chemical and complaince

Check whether the site has taken inputs from the SAFETY OFFICER for introduction of new chemicals.

Only compatible chemicals to be stored together. Check whether the site has conducted the study.

PPE requirements & do's & don'ts shall be clearly displayed near all chemical use areas. Check compliance

Chemical handlers shall be trained on the do's & don'ts and PPE requirements. Check records.

Chemical handlers shall handle chemicals as per do's & don'ts. Check compliance.

Check whether all chemical containers are closed during storage & transportation

Check whether all the chemical containers are having labels

Critical parts of the MSDS shall be displayed near the storage and handling areas of hazardous chemicals. Check compliance.

Check for the Safety instructions are display near place of work for hazardous chemicals.

Chemical storage locations (day stock and bulk stock) are as per OCP guidelines. Check compliance.

Check whether the chemicals are dispensed safely using manual pumps or tilting arrangement.

Check whether chemicals are transported in trolleys with secondary containment.

Check whether chemicals are stored with secondary containment.

Eye washers & safety showers shall be provided near chemical storage / handling area. Check compliance.

Check for caution displays near chemical handling areas.

Check whether all pumps transferring hazardous chemicals are provided with secondary containment. Check compliance.

Any safety sensitive changes shall be assessed, risks identified, mitigation plan implemented before the change is effected in the shop floor. Identify a recent change in the department and check for compliance to the above.

Any safety sensitive change shall be mitigated and discussed in the monthly department safety meeting.

Area PPE matrix is displayed at the entrance (visitor PPE & operator PPE). Check compliance.

Check PPE compliance in the shop floor

All employees shall be trained on basics of PPE. Interview and check awareness.

Safety shoes shall be worn in the production area. Check compliance.

PPE shall be in good usable condition. Check the condition of PPE used in the floor.

Check condition of racks, straight and without any damage

Check the awareness on general safety orientation with a contract employee

Job specific orientation (do's & don'ts) shall be provided to the contract workmen before deploying in the job.

Check the awareness among the contract employees in their Department Do's and Don’t's

General orientation of all visitors, guests shall be conducted by the security at gate. Interview a visitor or check compliance at gate register.

SAFETY OFFICER Cardinal norms shall be displayed in local language and english at appropraite locations. Check compliance.

All employees shall be trained on SAFETY OFFICER Cardinal norms and Non confirmity coaching process. Check records.

Check awareness of the people on the cardial norms

Violations shall be identified by the Supervisors, DSR's and HODs and coaching process followed. Check compliance.

Violations & coaching given by the line function shall be atleast twice versus those given by PLANT HEAD & SAFETY OFFICER.

PLANT HEAD & SAFETY OFFICER shall identify any violation during their walk through and coach the team.

All ladders / staircases to be hand rails on both sides. Toe guards to be provided for all working platforms. Check compliance.

All ladders to be identified for safe to use with Tagging

All ladders to be inspected for safe to use (Half-Yearly)

Inspection schedule to made and documented for All listed Ladders

Aisle way (1 m) to be available through out the plant for people movement. Aisle ways to be free from slip, trip, fall hazards. Check compliance.

All cleaning activity to have caution signages. Check compliance.

Annual STF survey to be done by the site and mitigation plan in place. Check actions taken in the site to mitigate STF issues.

Operations area shall not have slip, trip and fall hazards. Check compliance.

Display OHS policy in English and in local language at appropraite locations. Check compliance.

Interview any employee about his awareness on OHS Policy and his responsibility.

Interview any DSR to understand his roles & responsibility.

Interview any HOD to understand his roles & responsibility, knowledge of our Safety systems.

Check the functioning of departmental safety committees as per our Safety organisation OCP.

Check the Health & Safety Dash board and its livliness.

Interview an employees to understand whether he is aware of the accident & incident reporting process.

During the walk through identify any safety hazard and cross check whether it is captured in the department HIRA.

Check whether key hazards are identified, assessed and mitigated properly. (HIRA)

Interview any department employee to understand their knowledge on significant hazards in their department and actions taken.

Identify the status of mitigation plan against the significant hazards of the department.

Zero access guards to be in place for all rotating parts. Check compliance.

Check SAFETY TNI (Training Need Idendification) department wise

Check the compliance to SAFETY TNI (Training Need Idendification).

Check the compliance to basic safety orientation for all employees

Interview an employee and check the compliance to basic safety orientation

Check the compliance to fundamental safety modules as per SAFETY TNI

Interview an employee and check the compliance to fundamental safety training

Check whether all LTA (Loss Time Accident) & FAI (First Aid Injury) are investigated, communicated & acted.

Check for updation of Departmental Safety SHeet and discussion with employees and DSRs.

Display Emergency response plan in local language and English at appropraite locations.

All employees are trained on the emergency response plan. Interview an employee to check compliance.

Display department evacuation plan. Check compliance.

Emergency lights shall be provided to facilitate exit through escape routes. All critical panels shall have emergency lights.

Emergency lights shall be periodically tested and documented. Check compliance.

Mock drills are conducted as per plan and timing report is generated with action plan for improvement. Check records.

Mock drill action plan is shared and tracked for closure. Check compliance.

Emergency stop switches are highlighted and easily locatable in the panels. Check compliance.

Emergency escape routes are clearly identified towards the nearest assembly area. Check displays.

Fire hoses, fire extinguishers and other emergency equipment are prominently displayed and are unobstructed. Check compliance.

At least one first aider shall be available in each shift to support in case of any medical emergency. Check compliance and system to ensure compliance.

First aid team shall be identified with badges or any means. Check compliance.

Check the available of speed breakers in the plant (at corners / intersections). The speed limit inside the plant shall be by design.

Check the condition of speed breakers

Check the availablity of mirrors in the plant ( at corners / intersections ).

Check the condition and positioning of the mirrors.It should be big enough and high enough for the driver.

Check the resting places for drivers/cleaners. It shall have drinking water facilities, toilets nearby and ventilation. Sites shall plan localized resting place for different areas.

Check equipment register maintained for each contractor at the gate. Pick a equipment in the plant and cross check whether it is appearing in the register.

All the contractor equipments shall be inspected at gate (with a checklist) and only fit for purpose ones to be permitted. Check the compliance.

All the PTW facilities shall be numbered and stored properly.

Check whether all the safety harness have undergone half yearly statutory inspection.

Arc flash suit & gloves / Fibre toe safety shoes shall be available for the electricians.

Check the periodic inspection records of fire fighting equipments (Daily - hydrant pump, monthly visual inspections of fire extinguishers)

Check the periodic testing records of fire fighting equipments (quarterly -maintence record of hydrant pump & quarterly third party inspection on fire extinguishers)

All fire fighting equipments shall be in good working condition. Check physical compliance.

Check for driver's instruction in local language (language understood by the drivers & helpers)

Check for display of instruction at gate and other critical locations like rest areas. The display shall be legible and located at good location.

Check training attendance sheets of securities. The lesson plan shall include drivers instruction's and vehicle checklist.

Interview a security personnel to check his understanding of the driver instructions and vehicle checklist.

Check the check-sheet used at the gate to inspect incoming vehicles for its worthiness.

Check for evidence of checking the vehicle for its worthiness at gate.

Interview to understand the knowledge of security in vehicle worthiness check

Check for the availability of signed off document by SCM, PLANT HEAD, HR & SAFETY OFFICER at gate for maximum number (4NOS.) of vehicles to be allowed inside the plant.

Check to understand about the number of trucks inside the plant.

Interview of the security guards to monitor the awareness about the max. nos of trucks that can be allowed at a time and system they follow to ensure the same.

Check training attendance sheets of securities. The lesson plan shall include vehicle deviation report process (Supply chain, HR & Security).

Interview the security or the people responsible for the deviation process to check their awareness on the vehicle deviation process

Check the infrastructure near the security to store stoves & other materials from the truck.

Check the trucks inside the plant. They shouldn’t have stove, any flammable materials or objectionable materials.

Check the training attendance sheet of security and other nominated persons to support backing process.

Check for availability of minimum numbers of wheel chokes and its condition.

Check for displays to clarify the right way to place the wheel chokes.

Check for speed limit boards (10-15 kmph) at appropraite locations.

Check the list of nominated issuers, receivers, authorisers in the department (for PTW). The list shall be authorized by PLANT HEAD.

Check training attendance for the DSR's & nominated people. They shall have undergone the fundamental training on PTW program.

Check training attendance for the DSR's & nominated people. They shall have undergone the fundamental training on LOTO program.

Interview one of the signing authorities for a ongoing PTW to check his understanding of the hazards & precautions, procedure to perform the job.

All employees shall be trained on the basics of PTW system. Check the records to ensure all employees are covered in the training.

Interview a employee to understand his knowledge in PTW systems.

Check whether the DSR has conducted work in progress inspection on the Hot & Height work permits and initialled.

Check whether the SAFETY OFFICER has conducted work in progress inspection on the Hot & Height work permits and initiated.

PTW areas shall be barricaded with caution tapes and WIP boards.

Only fit for purpose facilities (ladder, safety harness, scaffolds, helmets etc) shall be used for permits. Check a ongoing permit whether the facilities are numbered and only fit for purpose is used.

LOTO shall be used for maintenance works. Check the compliance in an ongoing PTW.

Check the facilities available for performing LOTO.

Check the knowledge of LOTOTO within the team.

LOTO referance shall be included in the PTW sheet. Check for compliance.

Check whether list of authorised people, danger signage, LOTO information, PPE matrix are displayed in the entrance of panel room with contact details.

Check whether all eletrical panels has adequate illumination (Emergency lights shall also be provided for key panels)

Check whether appropriate clearance without any obstruction from all sides of the key panels and rubber mates as per IS standards

Check whether earthpits are tracable

Check whether earthpits are periodically tested (quarterly) & the test details are displayed near the earthpits.

Double earthing shall be available for electrical equipments ( ie motors etc ) & panels. Check compliance.

List of portable electrical cords shall be available and shall be complied.

Quarterly portable electrical cords inspections shall be conducted and only fit for purpose to be deployed in the plant.

List of portable electrical TOOLS shall be available and shall be complied.

Quarterly portable electrical TOOLS inspections shall be conducted and only fit for purpose to be deployed in the plant.

No visible damage to any electrical switches, panels or cables. Check compliance.

All security personnel shall be trained on fire fighting.

All employees shall be trained on basic fire fighting.

Conduct interviews and check awareness on the fire prevention and protection system.

Fire fighting arrangements map to be prepared and available at the security Office. Check Compliance.

At least one fire fighter shall be available in each area in each shift to support in case of any fire. Check compliance and system to ensure compliance.

Fire fighting team shall be identified with badges or any means. Check compliance.

Atleast 15% of employees shall be trained on fire fighting. Check compliance.

Display fire fighters present in the shift in the department & plant. Check compliance.

Periodic security patrolling shall be across the boundary. Check log book.

Interview a security to check his understanding on the fire prevention & protection systems and their role.