Information

  • Audit Title

  • Client / Site

  • Conducted on

  • Prepared by

  • Location
  • Personnel

Site Summary

1.0 Site EHS information and controls

  • 1.1 EHS signage and/or instructions at the entrance to the site advising what controls are in place? (PPE, sign in, restricted areas, etc)

  • 1.2 Was any form of EHS induction offered?

  • 1.3 Are visitors or new arrivals to the site escorted or hosted ?<br>

2.0 Factory entrance EHS instructions or controls

  • 2.1 Were factory signs or instructions easily observable at the common entrances?

  • 2.2 Are instructions or signage easy to understand (words or pictorial)?

  • 2.3 Was an outline of the hazards and/or restricted areas within the factory given?

3.0 Initial impressions and presentations of factory workarea

  • 3.1 Are walkways clearly marked and free from obstructions?

  • 3.2 Is the housekeeping standards aligned with 5S (demarcated, under control, everything has a place and all things in their place)?

  • 3.3 Are pedestrian flows observable through the production process? (looking if people walk everywhere and anywhere without consideration of the hazards)

  • 3.4 Workshop floors are without tools, waste and components left on them?

4.0 Work Environment

  • 4.1 Lack of/or inadequate amenities? (toilets, wash areas, lunch rooms, etc)

  • 4.2. Insufficient lighting?

  • 4.3 Insufficient ventilation (air flow natural, forced, other)?

  • 4.4 Adequate temperature controls ?(air conditioned, heated,etc)

  • 4.5 The site has adequate noise/ vibration/ dust or fume control processes in place?

5.0. Personal Protective Equipment (PPE)

  • 5.1 High levels of compliance with wearing PPE is observed? (PPE is worn when not watching and is part of the daily work)

  • 5.2. There appears to be a lack of, or inadequate PPE available within the work areas?

  • 5.3. Is there a formal and established system to issue, inspect, replace and monitor PPE? (ask operator to outline process)

  • 5.4 What systems are in place for the training in safe use, clean-up and inspection of PPE?

  • 5.5. PPE types, styles and locations are based on documented Risk/Hazard Assessments?

6.0 Working at Heights - general work areas

  • 6.1. Fall risks of 500mm or more? (including working platforms, pits, and trenches)

  • 6.2. Solid and stable edge protection systems for W@H work areas?

  • 6.3. Unsafe or incomplete edge protection?

7.0. Working at Heights - Ladders and/or portable working platforms

  • 7.1. Unsafe or damaged ladders or platforms in use or in the work areas?

  • 7.2. Unsafe positioning or behaviour when using ladders?

  • 7.3. Ladder not properly secured at the top and bottom?(extending 1mtr above work area)

  • 7.4. Ladder unsuitable for job? (e.g. metal ladder used for electrical work)

  • 7.5. Number of ladders in use within the factory?

  • 7.6. Is there a control system in place for the use of ladders? (Locked, PTW, etc)

  • 7.7. Are ladders used as an alternative to safer systems of work because of behaviour (I.e platforms, step platforms, etc)

  • 7.8. Do mobile platforms have a self locking wheel system or stabilisers?

8.0 Working at Heights - platforms

  • 8.1. Are platforms used as key tool for working at height?

  • 8.2. Work platforms are in good condition, well maintained and or good construction?

  • 8.3. Work platforms have stable feet or positioning systems (wheels are locked)?

  • 8.4. Solid and stable edge protection systems enclosing W@H work areas?

  • 8.5. Safe and complete edge protection is observed on all working platforms?

  • 8.6. Extendable fingers or other processes are used to narrow the gaps where possible? (Gaps of 200-300mm should be the limit)

  • 8.6.1. Extendable fingers or other processes are locked in place and are stable?

  • 8.7. There clearly observable Safe methods for accessing platforms? (Ladder, stairs, elevator, etc)

  • 8.8. Platform surfaces are non-slip material or coating?(diamond plate, non-slip paint, grill mesh, etc)

  • 8.9. Warning system activates when platform is mobile or raising/lowering? (Buzzer, flashing light, etc)

  • 8.10. There is an appropriate level and type of administrative controls in place? (Signage restricted entry, authorised operator list, etc)

  • 8.11. Safe W@H work practices observed? (Working underneath each other, gaps closed, harness used)

  • 8.12. Safe Work Load (SWL) are respected when using equipment? (tools, stored materials, number of persons)

9.0. Working at Height - Scaffolds

  • 9.1. Portable scaffold used within the production areas?

  • 9.2. There are defined training and/or licensing requirements for persons erecting scaffold?

  • 9.3. You can observe scaffolding set-ups which are safe, whether complete or under construction?

  • 9.3.1. Edge protection is in place and at adequate height (1mtr with mid rail)?

  • 9.3.2. Toe boards are in place?

  • 9.3.3. Safe access set up ( enclosed ladder, stairs, etc)?

  • 9.4. What inspection protocol for scaffold are in place (scaftags, labelling, Go/No Go, etc)?

  • 9.5. All scaffolding components are labelled with relevant safety standards for SWL, maintenance or other instructional material? (Refer any local stds)

  • 9.6. Safe Work Load (SWL) are respected? (tools, stored materials, number of persons)

10.0. Working at Height - Harness and Equipment

  • 10.1. Compatibility of hooks/equipment (retractable or rope, double action hooks, life lines, etc)?

  • 10.2. Equipment clearly identifable?

  • 10.3. Anchor points are labelled, known and safe?

  • 10.4. Adequate inspection protocol for equipment is in place (minimum 6 mthly)?

  • 10.4.1. Are quick how to use or inspection point charts available where equipment is used for the user?

  • 10.5. Adequate formal training for operators is in place?

  • 10.6. Equipment is respected and cared for? ( clean, hung up or stored well)

  • 10.7. Is equipment located in the area where it is needed? (Can operators easily access equipment)

11.0 Lifting Equipment - slings, chains and ropes

  • 11.1. Unsafe or damaged lifting equipment is easily identifiable and co-located with all other lifting equipment?

  • 11.2. Lifting equipment is unlabelled, no SWL or inspect tagging displayed?

  • 11.2. Loads lifted over persons, close proximity to obstacles incl. overhead power lines?

  • 11.3. The site can demonstrate a robust maintenance, testing and inspection regime for all equipment (no more than 6mthly intervals)?

  • 11.4. Daily or prior to use inspection protocol are in place? (Can be linked with TSV or other area inspections)

  • 11.5. Lifting equipment, including ropes, slings, chains, hooks are well cared for with storage practices? (Off ground, easily accessed, clean and sorted well)

12.0 Lifting Equipment - mobile or fixed cranes

  • 12.1. Plant in use is safe and not damaged?

  • 12.2. SWL information is clearly displayed on all equipment?

  • 12.3. The site has a robust maintenance, testing and inspection regime in place? (How are inspection records displayed or monitored, stickers on equipment?)

  • 12.4. LOTO procedures for cleaning, servicing and maintenance are displayed on the equipment?

13.0 Lifting Practices and Behaviours

  • 13.1. Has the site defined routine and non-routine lifting operations?

  • 13.2. How are PTW's and lifting plans used?

  • 13.3. The site clearly displays licensed and authorised operators?

  • 13.3.1. Competency or licensing is validated with site specific training and/or regulatory body?

  • 13.4. Load lifting is well co-ordinated to ensure activity is not performed over persons, close proximity to obstacles or under high risk environmental conditions?

14.0. Mobile Plant and Equipment - forklifts, scissor lifts, boom lifts, man cages, etc

  • 14.1. Equipment is good repair, safe and without concern? (including missing or damaged guards, self closing inward gates, latches, buzzers, tires, belly plates, etc).

  • 14.2. Incorrect plant /equipment for job? (e.g. Operators are not climbing over railings, leaning out of baskets, etc)

  • 14.2.1. Unsafe or incompatible attachments used with plant/equipment?

  • 14.3. Operators receive adequate training in safe operation, clean-up and maintenance of plant/equipment?

  • 14.4. All plant / equipment has dedicated parking allocated when not in use?

  • 14.5. Daily or prior to use inspection protocol are in place? (Can be linked with TSV or other area inspections)

  • 14.6. SWL or person capacity information is clearly displayed on all equipment?

  • 14.7. When the plant / equipment was used it was used in a safe manner and without deviation?

15.0. Machinery and Equipment - Carpentry shop

  • 15.1. The equipment used is safe and in good repair? (no missing or damaged guards)

  • 15.1.1. Has a guarding assessment been completed in the last 3 years?

  • 15.2. Incorrect equipment used for the job? (e.g. grinding discs for cutting, table saws for small cuts, etc)

  • 15.2.1. The equipment is modern or less than 10 yrs old? (old equipment may not achieve required safety requirements)

  • 15.3. Emergency STOP buttons or pull cords, etc on all machines and in close proximity to work location?

  • 15.4. Operators receive adequate training in safe operation, clean-up and maintenance of plant/equipment?

  • 15.5. The work area clearly displays authorised operators (photo of individual)?

  • 15.6. Each work centre/machine centre has written Risk Assessment and/or safe work instructions displayed?

  • 15.7. Isolation or LOTO procedures for cleaning or tool changing is clearly displayed?

  • 15.8. Safety devices or fail safe controls are regularly checked and validated? (Can equipment start with fail safe not engaged?)

  • 15.9. Upon entry to the work area are the EHS controls clearly displayed? (Example: PPE, restricted access, authorisation, etc)

  • 15.10. Has an occupational hygiene assessment been conducted to assess noise/ vibration/ dust impacts?

16.0. Machinery and Equipment - Core cutting / Core slitting lines

  • 16.1 The equipment used is safe and in good repair? (no missing or damaged guards)

  • 16.1.1. Has a guarding assessment been completed in the last 3 years?

  • 16.2. Emergency STOP buttons or pull-cords, etc on machines and in close proximity to work location?

  • 16.2.1. Are perimeter fences installed and interlocked? (outfeed and infeed areas)

  • 16.3. Operators receive adequate training in safe operation, clean-up and maintenance of plant/equipment?

  • 16.4 The work area clearly displays authorised operators and the restrictions for access (photo of individual)?

  • 16.4.1. Upon entry to the work area are the EHS controls clearly displayed? (Example: PPE, restricted access, authorisation, etc)

  • 16.5. Each work centre/machine centre has written Risk Assessment and/or safe work instructions displayed at point of entry?

  • 16.5. Isolation or LOTO procedures for cleaning or tool changing is clearly displayed?

  • 16.6. Safety devices or fail safe controls are regularly checked and validated? (Can equipment start with fail safe not engaged?)

  • 16.7. Has an occupational hygiene assessment been conducted to assess noise/ vibration/ dust impacts?

17.0. Machinery and Equipment - general plant / equipment (winding machines, motors, pumps, etc)

  • 17.1 The equipment used is safe and in good repair? (no missing or damaged guards)

  • 17.1.1. Has a guarding assessment been completed in the last 3 years? (external or internally)

  • 17.2. Emergency STOP buttons or pull-cords, etc on machines and in close proximity to work location?

  • 17.3. Operators receive adequate training in safe operation, clean-up and maintenance of plant/equipment?

  • 17.4 Where applicable do the work areas clearly displays authorised operators any restrictions for access (photo of individual)?

  • 17.4.1. Upon entry to the work area are the EHS controls clearly displayed? (Example: PPE, restricted access, authorisation, etc)

  • 17.5. Each work centre/machine centre has written Risk Assessment and/or safe work instructions displayed at point of entry?

  • 17.5. Isolation or LOTO procedures or points of action for cleaning or tool changing is clearly displayed?

  • 17.6. Safety devices or fail safe controls are regularly checked and validated? (Can equipment start with fail safe not engaged?)

  • 17.7. Has an occupational hygiene assessment been conducted to assess noise/ vibration/ dust impacts?

18.0. Electrical Risk Management and Procedures (low to medium voltage works)

  • 18.1. Does the site have defined Lock-out/tag-out (LOTO) procedures for electrical equipment?

  • 18.2. Is LOTO controlled to select personnel who are trained and authorised? (Review list of WESA and SESA)

  • 18.3. Does the site use a LOTO checklist with pictures or label on the equipment the isolation steps to define the 5 steps to electrical safety?<br>Separate<br>Isolate<br>Verify the Absence of Voltage (VAV)<br>Earth<br>Adjacent LIVE

  • 18.4. Are individual padlocks or group padlocks used? (Review who controls the keys)

  • 18.5. Are padlocks identifiable to the individual ? ( either with picture and name on the padlock or Danger Tag locked on)

  • 18.6. Is the work area sign posted or barricaded when LOTO is performed? ( some form of control is required to inform and prevent entry)

  • 18.7. Are rubber mats used when conducting LOTO or when electrical cabinets are opened? (Rubber matting can be permanently in place at the cabinet = best practice)

  • 18.8. Is a PTW issued for electrical works?

  • 18.9. Alstom personnel must validate any isolation or LOTO performed by a contractor prior to commencement?

19.0. Electrical Risk Management and Procedures (High Voltage and Test area)

  • 19.1. Does the site have defined Lock-out/tag-out (LOTO) procedures for HV electrical equipment?

  • 19.1.1. Is a PTW issued for electrical works?

  • 19.2. Is HV work limited to a select group of personnel who are trained and authorised? (Review list of WESA and SESA)

  • 19.3. Does the site have a defined LOTO protocol with pictures or label on the equipment outlining the isolation steps for electrical safety?<br>Separate<br>Isolate<br>Verify the Absence of Voltage (VAV)<br>Earth<br>Adjacent LIVE

  • 19.4. Are individual padlocks or group padlocks used? (Review who controls the keys)

  • 19.5. Are padlocks identifiable to the individual ? ( either with picture and name on the padlock or Danger Tag locked on)

  • 19.6. Is the work area sign posted or barricaded when LOTO is performed? ( some form of control is required to inform and prevent entry)

  • 19.7. Are rubber mats used at the key isolation and switching points when electrical cabinets are opened? (Rubber matting can be permanently in place at the cabinet = best practice)

  • 19.8 Are HV works undertaken by contractors validated by Alstom?

20.0. Hazardous Chemical (including fuel and oil)

  • 20.1. Unsafe storage location? (e.g. flammables near ignition sources, spills could enter stormwater drains, etc)

  • 20.2. Incompatible chemicals stored near each other? (flammables near combustibles, etc)

  • 20.3. Spill containment equipment and is co-located where needed for quick response?

  • 20.4. Safety Data Sheets (MSDS) is located near or accessible to where chemicals are stored / used?

  • 20.5. Are emergency procedures or basic instructions for spills posted at point of use / storage?

  • 20.6. Quantities stored in the factory areas are relative to daily/weekly usage or need? (review size and volumes of chemicals stored on the floor and in stores area)

  • 20.7. Ensure ventilation at storage and/or usage areas? (fumes should be minimal and not 100% reliance on PPE)

  • 20.8. Is appropriate PPE available and clearly instructed when using? (Refer MSDS and Risk Assessment)

  • 20.9. Suitable storage containers are used for all qualities of chemicals / liquids? ( containers must be labeled and not in drink bottles, etc)

21.0. Ergonomics and Manual Manual handling

  • 21.1. The site has identified all hazardous manual handling tasks and/or hazardous ergonomic conditions?

  • 21.2. Risk assessments of hazardous manual tasks has been conducted with operators and is visibly communicated across the shop floor for all users?

  • 21.3. The site has defined adequate risk controls? (example: it is not expect for operators to only 'take care', no engineering solutions have been implemented and controls are administrative only, etc)

  • 21.4. Has the site conducted formal manual handling training in risk controls and safe lifting/ team lifting techniques?

  • 21.5. The site has engaged the services of an external ergonomics specialists to help identify and define ergonomic risks for each work area and work activity?

  • 21.6. Ergonomic prevention and awareness is clearly communicated and visible throughout the worksite (look for posters, daily reminders or other awareness campaign material)?

  • 21.7. The site is able to articulate its ergonomic risk areas, injuries and performances to date to reduce the ergonomic risks?

22.0. Administrative Procedures and Risk Management

  • 22.1. Does the Site have an overall Site Safety Management Plan? ( the plan will outline what activities they are doing to achieve their directives, it is not just FR1 rates without actions listed)

  • 22.2. Site Risk Management Plan will list broadly all the high level risk areas along with controls such as Council and Regulatory Permit or Licensing, EPA, WHS, chemicals, bulk flammables and combustibles, Hot Works, Confined Space etc it can also be used to list all HRA relevant for ZDP.

  • 22.2.1 The Site has a formally documented Plan for defining Routine and Non-Routine Activities and/or when the conditions will determine when routine or not? (Plan is to list all ZD Themes and HRA as defined in Directive 01)

  • 22.3. There are site safety controls implemented to adequate ensure employees, contractors, visitors are inducted with a formally document system? (on-line system, passport or the like)

  • 22.4. Training, licenses, skills, experience are up to date, tracked well and visible or easily accessible on the shop floor ( training or skills matrix)?

  • 22.5. The site has a formally documented and practically working Risk Management System and Structure? (All risk information is where the risks are, the user can access and not in a managers office only)

  • 22.6. Formal and documented Risk Assessments are easily accessible and highly visible across the site ? (JSA - job safety analysis, Safe Work Method Statements (SWSM), etc)?

  • 22.7. Risk Assessment documents are practical and oriented with the end-user in mind? (Color, pictures, less words, 1-2 pages only and at the point of need are critical)

  • 22.8. Risk Assessments are systematically reviewed at least every 12 mths and involvement and validation by the end-user is demonstrable?

  • 22.9. Event or incident notification procedures and practices are implemented well with clear traceability? (Must also include Near miss, property damage and environmental)

  • 22.10. There is a good system in place which is visible and displayed on the shop-floor for routine inspections, monitoring, audits? (TSV,HSV, etc)

  • 22.11. The site has good, regular and wide spread consultative arrangements? (Meeting minutes are posted around the site, employee ideas are implemented, EHS representatives are visible and involved, employees are engaged in EHS when asked)

23.0. Contractor Procedures and Management

  • 23.1. Contractors develop and supply Safety Plans relevant for the work they are to undertake prior to commencing?

  • 23.2. Licences, insurances and permits are supplied, validated and reviewed before commencing?

  • 23.3. EHS induction and training is validated before work commences? (The EHS group ensure the right people have the rights skills and knowledge to do the job)

  • 23.4. Supervisory arrangements for EHS are clearly established and followed for the works when on site? (Project or Contractor owner must be visibly managing, deviations are low or nil and Safe Systems of work are in place, W@H, PPE, work area controls, etc)

  • 23.5. Risk Assessment documentation is supplied and is a critical element of the Safety Plan (JSA, Safe Work Method Statements (SWSM),etc) not just checklists without controls listed and checked?

  • 23.6. Risk Assessments are validated at the worksite on the day of use to ensure all relevant and observed hazards are accounted for (example: weather conditions, access ability, co-activity, mobile plant, etc)

  • 23.7. Routine inspections, monitoring and communications are integrated into the daily contractor management by the Project Leader and can be validated / demonstrated are being done?

24.0. Site Emergency Response procedures and processes

  • 24.1. There are robust and documented emergency plans for site?

  • 24.2. Emergency procedures are clearly displayed and highly visible across the site?

  • 24.3. The conducts training and/or rehearsals of emergency plans at least annually? (more so if identified within Site Risk Assessment)

  • 24.4 First aid kits / equipment is adequate for the site's needs?

  • 24.5 Emergency response equipment located around site in appropriate areas relevant to risk? (spill kits near oil risk, extinguishers near combustibles, etc)

  • 24.6 The site demonstrates a high level of preparedness for their emergency risks? (Highly visible controls, equipment and responsible personnel in place)

25.0. Site Traffic Management

  • 25.1 The site has developed a Traffic Management Plan (TMP)?

  • 25.1.1 The TMP takes into account all vehicle movements, inclusive of private / company vehicles which are mobile on site? (supplier reps, delivery drivers, etc)

  • 25.2 The TMP has be well communicated, the basic rules are visible and personnel are trained? (inclusive of contractors and visitors)

  • 25.3. There are adequate controls in place for the TMP? (physical barriers, bollards, speed limits, flashing lights, spotters, etc)

  • 25.4 The rules and/or instructions for the TMP are regularly observed and adhered to? (only minor deviations may be observed)

  • 25.5 Clearly marked walk ways and restricted areas are predominate and without ambiguity? (as a visitor you can clearly understand where to go or not)

  • 25.6. Personnel are observed adhering to the site TMP rules and controls in their general movements around the site (internal / external)? (consider actions a lunch time or shift changeover, do the hazards change)

26.0. Site Environmental Management

  • 26.1. The site has developed an adequate Environmental Management plan (EMP)?

  • 26.1.1 The site personnel are able to clearly identify the Environmental Risks and Hazards applicable for their site and their locations?

  • 26.2 The site EMP encompasses the risk posed by a neighbours activities and has taken measures to minimise any impact? (storage locations, pedistrian walk ways, atmospheric monitoring, etc)

  • 26.3 The site can demonstrate activities or investment to minimise their environmental impact relevant for their locations (rain water harvesting, flora or fauna mgt, water ways, etc) ?

  • 26.4 Waste management is observed as well under control? (segregation, labelling, adequate number and location of bins)

  • 26.5 General observations indicate the site has control of its appearances and good behaviours?(low levels of cigarette butts, plastic bottles, packaging materials, etc)

27.0. Facilities and Asset management - buildings, services and security

  • 27.1 The site has patrolling security 24/7? (make sure guards are roaming)

  • 27.2 There is a adequate boundary fence or controls?

  • 27.3 Site Access is controlled through a main checkpoint?

  • 27.4 Private use vehicles are not permitted to park on site? (observe flow of traffic, personnel and other movements)

  • 27.5 Are the guards employees of a 3rd party ? (observe familiarity with personnel and interaction during shift changes)

28.0 Zero Deviation Themes - general summary of each Road Map

  • EHS-001 Risk Management is a critical element in the planning, decision making, instructing and actioning across the site, with a clear overall structure of where the HRA are relevant and what actions are in place?

  • EHS-002 Contractor activities are well monitored and controlled with active leadership and support? (contractors are respect with no less care than Alstom employees)

  • EHS-003 The LOTO principles are clearly evident across the site, with good machine labelling and visual instructions? (LOTO is not just paperwork)

  • EHS-004 Electrical Safety and the controls are without concern and physical restrictions are clearly observable to prevent accidental entry to Electrical Risky conditions?

  • EHS-005 The protective controls used on Machine Safety are well controlled, guarding is not removable, adjustable or at the operators choosing, 'if it moves and can hurt someone - people are physically prevented to access' ?

  • EHS-006 Working @ Height risks are taken seriously and there is active leadership in ensure controls are in place and the site work practices are designed to minimise the need to W@H where ever possible? (things that can be done on the floor prior to install are considered, no behavioural deviations are observed)

  • EHS-007 There is no chance of entering, falling into or collapsing o any excavation activities on the site because of the good controls and planning implemented?

  • EHS-008 Lifting operations are well controlled with equipment in good condition, trained personnel and practices which do not put people or equipment in danger, (you can not enter lifting areas / activity zones )

  • EHS-009 Instructions, behaviour and physical controls for vehicle and pedestrian movements is easy to understand and follow visually?

Immediate or High Risk Corrective Actions

  • Enter any corrective actions that will be or have been undertaken as a result of observed High Risk Activity or deviations during review.

Sign Off

  • On site representative

  • Auditor's signature

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