Annual Facility Safety Audit for Feed and Grain

• Facility Name

• Audit Date

  Date

• Auditors

• Section 1 = Safety & Health Administration - Eligible Points = 21

• Section 2 = Regulatory Compliance - Eligible Points = 122

• Section 3 = Machine Specific - Eligible Points = 5

• Section 4 = Equipment Inspections - Eligible Points = 14

• Section 5 = Air Monitoring - Eligible Points = 1

• Comments

Reporting and Tracking of Accidents and Illnesses

• A. Current OSHA log (Form 300) is maintained and up to date

  Yes

  No

  N/A

• Comments

• B. Completed OSHA logs are maintained and available for review for the previous five years

  Yes

  No

  N/A

• Comments

• C. An OSHA Form 301 (Injury and Illness Incident Report) or adequate State Workers' Compensation First Report of Injury is on file for the current year each injury or illness

  Yes

  No

  N/A

• Comments

• D. OSHA Form 301 (or State Workers' Compensation First Report of Injury) is on file and maintained for the previous five years

  Yes

  No

  N/A

• Comments

• E. The completed OSHA 300-A Summary forms is posted in a prominent place between February 1 - April 30

  Yes

  No

  N/A

• Comments

• F. Completed OSHA 300-A summary forms are maintained for the previous 5 years

  Yes

  No

  N/A

• Comments

• G. OSHA required information is readily accessible to meet 4 hour accessibility requirement. (OSHA 300 and 300-A forms)

  Yes

  No

  N/A

• Comments

Medical/Treatment

• A. First Aid/CPR/AED training is completed for site personnel with documentation

  Yes

  No

  N/A

• Comments

• B. Standing orders have been developed by a physician and reviewed every two years with documentation

  Yes

  No

  N/A

• Comments

• C. First aid kits available and appropriately stocked

  Yes

  No

  N/A

• Comments

Incident Reporting and Investigation Procedures

• A. Supervisor incident reports are completed for all OSHA record-able accidents and near misses deemed serious

  Yes

  No

  N/A

• Comments

• B. Incident Review Boards are conducted for any OSHA record-able, property damage, involving powered industrial equipment or other incidents with potential for serious injury. (IRB form completed)

  Yes

  No

  N/A

• Comments

Safety Committee

• A. Safety Steering team meetings are held monthly with documentation

  Yes

  No

  N/A

• Comments

• B. Facility Safety teams meet at least on a monthly basis with documentation & include ergonomics

  Yes

  No

  N/A

• Comments

• C. Facility Safety team members are provided documented training on their responsibilities

  Yes

  No

  N/A

• Comments

• D. Facility Safety teams conduct periodic audits of the facility to include ergonomics

  Yes

  No

  N/A

• Comments

• E. Process Safety Management (PSM) meetings are held at least on a monthly basis with documentation

  Yes

  No

  N/A

• Comments

• F. Facility safety/engineering/maintenance planning meetings are held on a weekly basis

  Yes

  No

  N/A

• Comments

Facility Safety Inspections

• A. Daily safety inspections are conducted and documented. Deficiencies identified are corrected with documentation

  Yes

  No

  N/A

• Comments

• B. Monthly safety inspections are conducted and documented. Deficiencies identified are corrected with documentation

  Yes

  No

  N/A

• Comments

• C. Quarterly facility inspections are conducted and documented. Deficiencies are corrected and documented

  Yes

  No

  N/A

• Comments

Fire Prevention and Protection

• A. Fire extinguisher training is conducted on an annual basis for authorized users through the Alchemy LMS

  Yes

  No

  N/A

• Comments

• B. Fire extinguishers are inspected monthly with documentation

  Yes

  No

  N/A

• Comments

• C. Fire extinguishers are inspected annually by a third party with documentation

  Yes

  No

  N/A

• Comments

• D. Fire extinguishers are not blocked

  Yes

  No

  N/A

• Comments

• E. Maximum travel distance for a fire extinguisher is 75 feet

  Yes

  No

  N/A

• Comments

• F. Fire extinguishers are not mounted above 5 feet and no less than 4 inches off the floor

  Yes

  No

  N/A

• Comments

• G. Authorized employees receive initial "Hot Work" training with refresher training every three years through the Alchemy LMS

  Yes

  No

  N/A

• Comments

• H. Hot Work Permits are fully utilized and completed accurately

  Yes

  No

  N/A

• Comments

• I. Areas requiring hot work permits are identified with documentation

  Yes

  No

  N/A

• Comments

• J. Hot Work Permits are maintained onsite for 30 days

  Yes

  No

  N/A

• Comments

• K. The hot work program and completed hot work permits (30 days) are evaluated on an annual basis with documentation

  Yes

  No

  N/A

• Comments

• L. Sprinklers Systems and alarms are inspected quarterly by a third party with documentation

  Yes

  No

  N/A

• Comments

• M. Annual Pump test are completed for sprinkler systems by a third party with documentation

  Yes

  No

  N/A

• Comments

• N. Sprinkler pumps are test run weekly (in-house) with documentation

  Yes

  No

  N/A

• Comments

• O. Monthly valve position inspections for each sprinkler riser is conducted monthly in-house with documentation

  Yes

  No

  N/A

• Comments

Walking Surfaces

• A. All work platforms, stairs, ladders and mezzanines are designed according to Mountaire and OSHA construction standards

  Yes

  No

  N/A

• Comments

• B. Floors are in good condition and slip resistant

  Yes

  No

  N/A

• Comments

• C. Drain grating is in good condition and slip resistant

  Yes

  No

  N/A

• Comments

• D. Signage and warning cones are used during floor cleaning

  Yes

  No

  N/A

• Comments

Personal Protective Equipment (PPE)

• A. Job/task specific PPE hazard assessments have been performed to determine PPE needs

  Yes

  No

  N/A

• Comment

• B. Job/task specific PPE hazard assessments are reviewed on an annual basis

  Yes

  No

  N/A

• Comment

• C. Observations indicate that employees are wearing PPE as required by job task

  Yes

  No

  N/A

• Comment

Hearing Conservation

• A. Sound levels have been measured and documented for all areas of the facility (annually)

  Yes

  No

  N/A

• Comments

• B. Warning signs are posted in high noise areas

  Yes

  No

  N/A

• Comments

• C. Audiometric examinations are conducted for affected employees on an annual basis

  Yes

  No

  N/A

• Comments

• D. The OSHA hearing conservation program standard is posted in the facility

  Yes

  No

  N/A

• Comments

• E. The written hearing conservation program is audited on an annual basis

  Yes

  No

  N/A

• Comments

• F. Hearing conservation training is conducted on an annual basis

  Yes

  No

  N/A

• Comments

• G. Employees with hearing shifts are retrained on the proper use of hearing protection with documentation

  Yes

  No

  N/A

• Comments

Hazard Communication

• A. All chemicals on-site are pre-approved by Safety & Environmental and in the MSDS online system

  Yes

  No

  N/A

• Comments

• B. All containers are clearly labeled including the appropriate warnings and pictograms

  Yes

  No

  N/A

• Comments

• C. Chemicals not in original container and not for immediate use have GHS labels (pictograms, signal word & precautionary statements)

  Yes

  No

  N/A

• Comments

• D. MSDS online icon is available on Kiosks

  Yes

  No

  N/A

• Comments

• E. The written hazard communication program is audited on an annual basis

  Yes

  No

  N/A

• Comments

Hazardous Energy Control - Lockout/Tagout

• A. Types of locks utilized are identifiable and issued to authorized employees

  Yes

  No

  N/A

• Comments

• B. All authorized employees are properly trained on the lockout/tagout program through the Alchemy & Training Department (initial & annual refresher)

  Yes

  No

  N/A

• Comments

• C. All authorized employees are trained on the "LOTO Observation Skills Steps" annually with documentation (form developed)

  Yes

  No

  N/A

• Comments

• D. Written lockout/tagout procedures have been developed for each piece of equipment addressing all types of energy as required

  Yes

  No

  N/A

• Comments

• E. Locations for lockout/tagout disconnects are listed for each unit in the written procedure

  Yes

  No

  N/A

• Comments

• F. An annual inspection of energy control procedures will be conducted to include verification of authorized personnel understanding of LOTO machine specific procedures (documented)

  Yes

  No

  N/A

• Comments

• G. Line opening permits are maintained on-site for 1 year

  Yes

  No

  N/A

• Comments

• H. Annual review of completed line opening permits is completed with documentation

  Yes

  No

  N/A

• Comments

Powered Industrial Equipment

• A. Authorized pallet jack operators receive initial training with refresher training every 2 years (documented)

  Yes

  No

  N/A

• Comments

• B. Authorized fork lift operators receive initial training with refresher training every 2 years (documented)

  Yes

  No

  N/A

• Comments

• C. Pallet jack pre-trip inspections are completed with documentation

  Yes

  No

  N/A

• Comments

• D. Fork lift pre-trip inspections are completed with documentation

  Yes

  No

  N/A

• Comments

• E. Forklifts are equipped with backup alarms, horns, lights & fire extinguishers

  Yes

  No

  N/A

• Comments

• F. All forklifts are equipped with overhead protection and seat belts

  Yes

  No

  N/A

• Comments

• G. Pallet jack and fork lift operators are carrying their certification license

  Yes

  No

  N/A

• Comments

• H. Seat belts are being worn on all forklifts

  Yes

  No

  N/A

• Comments

• I. Authorized skid steer operators receive initial training with refresher training every 2 years (documented)

  Yes

  No

  N/A

• Comments

• J. Skid steer pre-trip inspections are completed with documentation

  Yes

  No

  N/A

• Comments

• K. Authorized articulating boom operators receive initial training with refresher training every 3 years (documented)

  Yes

  No

  N/A

• Comments

Emergency Action Plans - Egress

• A. An Emergency Action Plan has been developed and updated when facility changes are made. (fire, chemical, weather, bomb threat & medical emergency)

  Yes

  No

  N/A

• Comments

• B. The Emergency Action Plan is reviewed on an annual basis with documentation

  Yes

  No

  N/A

• Comments

• C. Exit signs are illuminated with a minimum of 5 foot candles of light

  Yes

  No

  N/A

• Comments

• D. Doors that are not exits are marked "Not an Exit"

  Yes

  No

  N/A

• Comments

• E. Exits are not blocked

  Yes

  No

  N/A

• Comments

• F. Egress exit doors are not locked or equipped with appropriate panic bars

  Yes

  No

  N/A

• Comments

• G. Annual fire evacuation drills are conducted by shift with documentation (includes head count)

  Yes

  No

  N/A

• Comments

• H. All supervisors are trained on emergency evacuation procedures on an annual basis with documentation

  Yes

  No

  N/A

• Comments

• I. Evacuation assembly areas are designated (Signage for processing facilities)

  Yes

  No

  N/A

• Comments

• J. Emergency lighting is in working order and inspected on a monthly basis with documentation

  Yes

  No

  N/A

• Comments

• K. Local Fire Department has conducted site visit within the last three years with documentation

  Yes

  No

  N/A

• Comments

Bloodborne Pathogens

• A. Bio-waste bags and/or sharps containers are labeled and utilized

  Yes

  No

  N/A

• Comments

• B. Authorized employees are trained on an annual basis through Alchemy (medical, janitorial, first aid & others)

  Yes

  No

  N/A

• Comments

• C. Documentation exists that hepatitis vaccinations are offered to employees

  Yes

  No

  N/A

• Comments

• D. Personal protective equipment (PPE) has been issued to all bloodborne pathogen responders

  Yes

  No

  N/A

• Comments

Confined Space Entry

• A. All authorized employees are trained on confined space entry through the Alchemy LMS every three years

  Yes

  No

  N/A

• Comments

• B. Rescue training is completed for authorized confined space trained employees with documentation (if needed)

  Yes

  No

  N/A

• Comments

• C. Air monitoring equipment is maintained and available on-site for any confined space entries

  Yes

  No

  N/A

• Comments

• D. A master list of confined spaces is maintained

  Yes

  No

  N/A

• Comments

• E. All confined spaces are posted with appropriate signage

  Yes

  No

  N/A

• Comments

• F. Rescue equipment is maintained or available on-site at time of any confined space entry. (confined spaces not declassified)

  Yes

  No

  N/A

• Comments

• G. Confined space permits are maintained on-site for one year

  Yes

  No

  N/A

• Comments

• H. The confined space program and confined space permits are evaluated on an annual basis with documentation

  Yes

  No

  N/A

• Comments

Respiratory Protection

• A. Respiratory protection training is conducted through the Alchemy LMS on an annual basis

  Yes

  No

  N/A

• Comments

• B. Appendix D form is completed for all employees wearing respirators on a voluntary basis

  Yes

  No

  N/A

• Comments

• C. Respiratory physicals are performed on an annual basis with documentation of clearance from our medical provider

  Yes

  No

  N/A

• Comments

• D. Fit testing is performed for all employees wearing respirators. Requires documentation by each type of mask/regulator

  Yes

  No

  N/A

• Comments

• E. Respirators are clean and stored in an appropriate container or bag

  Yes

  No

  N/A

• Comments

Formaldehyde

• A. New hire orientation training for Formaldehyde is completed for affected employees through the Alchemy LMS to include temporary and contract workers

  Yes

  No

  N/A

• Comments

• B. Annual formaldehyde training is completed for authorized employees through the Alchemy LMS to include temporary and contract workers

  Yes

  No

  N/A

• Comments

• C. Warning signage is utilized to identify hallways/rooms during formaldehyde use

  Yes

  No

  N/A

• Comments

• D. Bulk storage of formaldehyde has appropriate warning signage

  Yes

  No

  N/A

• Comments

• E. Procedures are developed for dispensing of formaldehyde to include wick cleaning and emergency spills

  Yes

  No

  N/A

• Comments

• F. Medical Disease physicals are performed as based on air monitoring results. (above STEL=2.0 ppm, above AL=.5 PPM TWA)

  Yes

  No

  N/A

• Comments

Machine and Power Transmission Guarding

• A. Blades of fans less than seven (7) feet above the floor or working level are guarded. The guard must not have openings larger than one-half (1/2) inch

  Yes

  No

  N/A

• Comments

• B. Power transmission equipment (pulleys/chains/gears/sprockets) less than seven (7) feet above the floor or working level are guarded front and back

  Yes

  No

  N/A

• Comments

• C. All exposed parts of shafts less than (7) feet above the floor or working level is protected by casing enclosing the shaft

  Yes

  No

  N/A

• Comments

• D. Projecting shaft ends have smooth edges and do not project more than one half diameter of the shaft unless guarded by non-rotating caps

  Yes

  No

  N/A

• Comments

• E. Unused shaft keyways are filled or covered

  Yes

  No

  N/A

• Comments

Contractor Safety

• A. "Contractor Safety Approval" form is completed for each contractor

  Yes

  No

  N/A

• Comments

• B. Periodic audits are conducted of contractors on-site work with documentation

  Yes

  No

  N/A

• Comments

Fall Protection

• A. Initial fall protection training is provided to authorized employees with refresher training every 3 years through the Alchemy LMS

  Yes

  No

  N/A

• Comments

Electrical Safety

• A. No observed missing electrical covers

  Yes

  No

  N/A

• Comments

• B. Electric panels are not blocked (3 feet)

  Yes

  No

  N/A

• Comments

• C. Electrical panels are clearly labeled

  Yes

  No

  N/A

• Comments

• D. Electric panel covers/doors/troughs are not missing anchor screws with all knockouts sealed

  Yes

  No

  N/A

• Comments

• E. Electrical panel blanks are properly covered

  Yes

  No

  N/A

• Comments

• F. Electrical conduit is utilized for all permanent machinery and equipment

  Yes

  No

  N/A

• Comments

• G. Extension cords are in good condition with appropriate ground plugs

  Yes

  No

  N/A

• Comments

• H. GFCI's are utilized for construction like work. (extension cords for portable power tool, ect...)

  Yes

  No

  N/A

• Comments

• I. Arc flash analysis and appropriate labels are posted on all electric panels

  Yes

  No

  N/A

• Comments

• J. Arc flash analysis is re-certified every 5 years with documentation

  Yes

  No

  N/A

• Comments

• K. Initial NFPA 70 E training has been conducted through the Alchemy LMS with refresher every 3 years for affected personnel

  Yes

  No

  N/A

• Comments

• L. Arc flash PPE is available on-site with reasonable access

  Yes

  No

  N/A

• Comments

Shipping and Loading Docks

• A. Wheel chocks are available and utilized

  Yes

  No

  N/A

• Comments

• B. Daily pre-trip inspections are conducted for jockey trucks with documentation

  Yes

  No

  N/A

• Comments

• C. Dock doors are lighted and identified

  Yes

  No

  N/A

• Comments

• D. Dock plates and levelers are in good condition

  Yes

  No

  N/A

• Comments

• E. Docking safety systems are in good working condition (lights)

  Yes

  No

  N/A

• Comments

Grain and Feed Handling

• A. All pit grates have an opening grid of 2.5 inches or less

  Yes

  No

  N/A

• Comments

• B. Good housekeeping exists which includes evidence or 1/8 inch or less of grain dust

  Yes

  No

  N/A

• Comments

• C. A written program for emergency action plans for grain and feed handling has been established (fire, explosion, rescue, ect...)

  Yes

  No

  N/A

• Comments

• D. Employees have been trained on emergency action plans for grain and feed handling situations with documentation

  Yes

  No

  N/A

• Comments

• E. Affected employees have been trained on bin entry procedures with documentation

  Yes

  No

  N/A

• Comments

• F. A written housekeeping program has been developed by area/equipment with documented compliance

  Yes

  No

  N/A

• Comments

• G. A written program for preventive maintenance established for grain legs and key equipment with documentation of compliance

  Yes

  No

  N/A

• Comments

• H. Rail/train car safety procedures have been developed with documented training

  Yes

  No

  N/A

• Comments

• I. Bin entry permits are maintained for 1 year

  Yes

  No

  N/A

• Comments

• J. Annual review of the bin entry procedure to include bin entry permits is completed with documentation

  Yes

  No

  N/A

• Comments

Machine Specific and Task Training

• A. Verify new hire orientation is being conducted per approved playlist/learning plan. (random select 20 - processing, 5-Live & 2-Grain)

  Yes

  No

  N/A

• Comments

• B. Monthly awareness safety training is conducted for the entire facility with documentation

  Yes

  No

  N/A

• Comments

• C. Boiler low water cut-out safeties are tested daily with documentation

  Yes

  No

  N/A

• Comments

• D. Boiler daily operating pressure logs are maintained to ensure safe parameters with documentation

  Yes

  No

  N/A

• Comments

• E. Procedures have been developed for pallet jack battery changing with documented training

  Yes

  No

  N/A

• Comments

Equipment Inspection

• A. Engineered fall protection systems are inspected on an annual basis by a third party with documentation

  Yes

  No

  N/A

• Comments

• B. Safety harnesses & lanyards inspected annually with documentation (in-house)

  Yes

  No

  N/A

• Comments

• C. Self retracting lifelines (SRL's) are inspected on an annual basis with documentation (non-engineered system, in-house)

  Yes

  No

  N/A

• Comments

• D. Anchor (slings) hardware inspected annually with documentation (in-house)

  Yes

  No

  N/A

• Comments

• E. Ladders are inspected on annual basis by safety with documentation

  Yes

  No

  N/A

• Comments

• F. Emergency eye wash and showers are available and inspected on a monthly basis with documentation

  Yes

  No

  N/A

• Comments

• G. Emergency eye wash and showers are clean and functioning

  Yes

  No

  N/A

• Comments

• H. Hoist are inspected on an annual basis by a third party with documentation

  Yes

  No

  N/A

• Comments

• I. Hoist beams are marked with load rating

  Yes

  No

  N/A

• Comments

• J. Storage mezzanines have signage for load rating

  Yes

  No

  N/A

• Comments

• K. Bench grinders have all the guards with tool rest not to exceed 1/4 inch and shatter guard not to exceed 1/8 inch

  Yes

  No

  N/A

• Comments

• L. Drill press is mounted to the floor and has bit guarding

  Yes

  No

  N/A

• Comments

• M. Welders are in good condition including leads, power cords, and plugs

  Yes

  No

  N/A

• Comments

• N. Oxygen cylinders are stored at least 20 feet from flammable tanks or separated by 5 foot high - one hour fire barrier

  Yes

  No

  N/A

• Comments

Air Monitoring

• A. Personal air monitoring conducted every two years for dust with the results posted. Note: Change in process requires new monitoring. (Live Hang, Hatchery & Feed Mill)

  Yes

  No

  N/A

• Comments