Berry Blue Element - Leaders Inspection - Berry SCUK

Title Page

The Berry Blue Element Leaders Inspection is to be completed monthly on each site by the leadership team on site. The exact content of the inspection will be dictated by the month the inspection is taking place and an annual schedule is published to ensure good notice of your time to complete the inspection tour.
The inspections will check compliance of the site to specific elements of the Berry Blue EHS audit - it is not a copy of the Berry Blue EHS audit. It is designed to take approximately 60-90 minutes to complete. You will not check all twenty elements during your inspection - only those elements shown to you when you start the inspection. If you have any questions please ask your manager or the EHS Manager.
The health and safety audit programme operated throughout Berry Global's CPI Division is known as the Berry EHS Blue audit programme. The core structure of the audit has a total of 20 Elements which align with the Berry Global EHS Framework. The 20 elements are shown beow and are auditted annually by Berry and Willis Towers.

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Blue Element Inspection Section:
The inspection you are doing today DOES NOT inspect all 20 Elements. The elements have been divided up into PARTS and distributed across 12 months as per the table below. You only need to select the month you are conducting the inspection and the audit will automatically select only the Elements and questions needed for that month. Read each question and answer as indicated for each (Yes/No/ N/A; or slider scoring). Take photos to show evidence of the inspection and add notes/comments where required. Actions can also be raised and this is encouraged.
If you see something that needs urgent attention please address it yourself (if safe to do so) or raise as an urgent hazard and inform the site management immediately.

Good Practice and Improvement Areas:
During your tour make a note of any good practices seen that should be recognized and celebrated. Also make a note of any improvement you believe are needed - take photo(s) and raise an appropriate action.

EHS Leadership Tour Conversation Section:
Driving and improving safety behaviors is an important part of developing a good safety culture on site. It is important for leadership to engage with staff, using positive safety conversations, to obtain feedback and enable safety improvements. Please take the opportunity of the Blue Element inspection tour to engage with at least one member of staff and record what was discussed and any actions as an outcome. Engage with an employee and record the conversation with some simple notes and any actions required.
Site inspected:
Conducted on date:
Audit completed by:
Location

Berry Blue Element Inspection

Select Berry Blue Elements for Inspection

Please select the month for this inspection:
- January
- February
- March
- April
- May
- June
- July
- August
- September
- October
- November
- December

PART 1: Elements 1 - 2 - 3 - 10 - 18

Element 1: Leadership and Accountability

The site leadership team should be working to agreed standards, policies and with plans and objectives for continuous improvement. Policies, responsibilities, plans and objectives should be displayed and communicated to all on site.
1.1 Is the EHS Policy displayed on site for both staff and visitors?
1.2 Are the Berry EHS Principles displayed on entry to and around the site?
1.3 Are the EHS responsibilities shown on notice boards or flip folders on site?
1.4 Is the site EHS Scorecard displayed on the noticeboard, and does it show the most recent full month data?

Element 2: Employee Engagement and Behavioural Safety

The business should be engaging with all staff to communicate EHS issues and obtain feedback and ideas for possible improvement. This is done through regular inspections, Factory Meetings and RoES meetings. These should be recorded.
2.1 Ask to see the latest Factory Meeting minutes (Operations Manager). Are they being completed every month?
2.2 Ask EHS Manager for copy of RoES (Representatives of Employee Safety) meeting minutes. Are actions listed and being progressed?

Element 3: Regulatory Compliance

The business is subject to all the national (and international) regulations and legislation that applies to a manufacturing business. These regulations should be known and reviewed in a regulation review system. This is managed by the EHS Manager and for this section of the inspection you will need to discuss this with the EHS Manager.
3.1 Ask the EHS Manager to show you the Regulations Legislation review system.
3.2 Are actions in place for any non-compliant areas?
3.3 Check two or three actions. Are these actions all completed on target date?

Element 10: Management of Change

In its most basic form, a Management of Change (MoC) system simply ensures that a risk assessment is carried out before a change is made to anything. This could be a change to a product, material, equipment or someone’s job. We must make sure that, for any changes that may affect our health and safety, we follow a system that ensures we record the change, do a formal risk assessment and manage the actions that are required to make sure the change does not increase the risk of an accident. To inspect this element you will need to talk with the EHS Manager.
10.1 What Management of Change projects are listed for the site? Please list them:
10.2 Select a MoC project. Are all the actions within required date?

Element 18: Health and Wellness

As well as general safety, the company has a duty of care for the heath and wellness generally of all employees. This includes provision of First Aid and suitable equipment and facilities.
18.1 Is there a list of trained First Aiders shown throughout the site?
18.2 Check two or three items from a selected First Aid kit. Are they each within their expiry date?
18.3 Noise: Is there signage on entry to production areas that hearing protection must be worn?
18.4 Noise: Are all employees wearing hearing protection in production?
18.5 Noise: Is there signage on entry to yard/warehouse areas to instruct people that hearing protection should be removed.

PART 2: Elements 6 - 8 - 14

Element 6: Corrective and Preventative Actions

Where issues are found or feedback is received, the site needs to formally record any actions required. These Corrective and Preventative Actions (CAPAs) should be formally recorded and have timescales to complete.
6.1 Check the site EHS Scorecard (site EHS board). Does this show the percentage of hazards resolved (Hazard Resolution) for the month at 90% or more?
6.2 Does the Scorecard show the percentage of hazards resolved (Hazard Resolution) for rolling 12 months (small chart) at 90%?
6.3 Do the Hazard Metrics on the Scorecard show number of hazards reported per person at the required level of 6 per person per year? (Note: This pro rate. E.g. if 3 months through the Oct-Sep year divide the number by 3 and multiply by 12 to give full year rate).
6.4 Check the site EHS Scorecard (site EHS board). Does this show Risk Management for FM Global as Blue?
6.5 Ask the Factory Manager to show you the oldest open hazard. Is there an action plan (with date) for closing this open hazard?

Element 8: Training and Communications

The training at all sites is recorded using the Mitrefinch TMS system. All Factory Managers and Supervisors have access to TMS and can provide a training matrix by department to show who is trained in what activities. For this inspection you will need to speak with the Factory Managers / Supervisors to review the training matrix.
8.1 Check the training matrix for Operators (Day or Night Shift). Is all the training approximately 90% up to date or scheduled to be up to date? (out of date will show as red on the matrix).
8.2 Production Staff: Is Induction Training shown as completed for all staff?
8.3 Production Staff: Is Manual Handling training shown as completed and within date for all staff?
8.4 Production Staff: IS SWP 8.34 training up to date for all production staff?
8.5 Check the training matrix for Technical. Is all the training approximately 90% up to date or scheduled to be up to date? (out of date will show as red on the matrix).
8.6 Technical: Is SWP 8.33 training up to date for all Technical staff?
8.7 Ask who changes the blades on the bulk granulator. Record their name. Is SWP 8.04 training up to date for this person?
8.8 Check the training matrix for Warehouse. Is all the training approximately 90% up to date or scheduled to be up to date? (out of date will show as red on the matrix).
8.9 Warehouse: Is SWP 8.08 training up to date for all Warehouse staff?
8.10 Warehouse: Is SWP 8.36 training up to date for all Warehouse staff?
8.11 Check the pillar/pedestal drill in the engineering bay. Select one person from the authorised user list. Is this person’s training for SWP 8.38 up to date in the training matrix?
8.12 Communications: Are the RoES Safety Group members shown on the EHS noticeboard?
8.13 Communications: Are there any First Alert notices shown on the EHS noticeboard?
8.14 Communications: Are the Top 10 Risk projects shown on the noticeboard and are they up to date (oldest should be previous month)?
8.15 Communications: Are the information screens working on site?
8.16 Ask a staff member if they know the days since last recordable accident on site (this is displayed on board outside the entrance to the site)?

Element 14: Emergency Preparedness and Fire Prevention

The site has an emergency plan (Business Continuity Plan) to manage emergency situations. There are also regular Fire Assessments and inspections to ensure remedial actions are taken where necessary to be prepared for an emergency situations.
14.1 Speak with the Operations Manager and ask to see the latest version of the Business Continuity Plan. Check with the Quality Manager – is this the correct date and version of the Business Continuity Plan?
14.2 Fire: Check with the Operations Manager or the Factory Manager for the latest copy of the annual Fire Risk Assessment. Is this in date (should be within one year)?
14.3 Fire: Have actions shown on the Fire Risk Assessment been completed/in progress?
14.4 Fire: Check with the Factory manager when the most recent Fire Drill was completed. Was it done within the last 6 months?
14.5 Fire (Yard Area): Check the yard areas. Are all pallets etc stored away from the building to prevent risk of fire?
14.6 Fire (FLT Charging Area). Check the FLT charging areas. Is it free from wooden pallets, debris and other flammable items?

PART 3: Elements 7 - 9 - 15

Element 7: Housekeeping and 5S

A site with well maintained housekeeping will inherently be a safer environment for all to work in. This section of the inspection will assess: the general standard of housekeeping; the progress being made on the 5S projects around the site; and records of housekeeping to ensure standards are being met.
7.1 General: Are walkways in production clearly marked and uncluttered? (Pallets, cartons, equipment etc).
7.2 General: Are walkways in production free of debris that could cause slips such as oil, granules, spilled caps etc?
7.3 Ask to see a weekly Managers/Supervisors 15-minute recorded inspection for the previous week. Has this been completed?
7.4 Check the cleaning records for the Production area. Are these completed and up to date?
7.5 Are the Housekeeping boards accessible and do they contain all necessary equipment?
7.6 Use the slider to score the production area housekeeping between 0 (Poor) and 10 (Good).
7.7 Check the cleaning records for the Engineering bay/room. Are these completed and up to date?
7.8 Use the slider to score the Engineering bay/room housekeeping between 0 (Poor) and 10 (Good).
7.9 If applicable, check the cleaning records for the Toolroom. Are these completed and up to date?
7.10 Use the slider to score the Toolroom area housekeeping between 0 (Poor) and 10 (Good).
7.11 Check the cleaning records for the Warehouse / Yard areas. Are these completed and up to date?
7.12 Are pallets stacked safely and stored at least 10 metres (or other required distance) away from buildings?
7.13 Use the slider to score the warehouse / yard housekeeping between 0 (Poor) and 10 (Good).
7.14 5S: The sites are implementing a specific 5S system and this will be at various stages in different areas of the site. Is there a 5S information board on site?
What stage is the site at on its 5S journey? List: SORT – SET – SHINE – STANDARDISE – SUSTAIN ?
Check within a 5S area of the site. Are all equipment, parts, cartons, pallets etc. in their correctly identified areas?

Element 9: Personal Protective Equipment

Personal Protective Equipment (PPE)is issued to all staff according to the activities they will be engaged in. PPE can include: Hats; gloves (various types); shoes; Hi-Viz vests/coats; masks; safety glasses; visors; general uniform; ear protection). At the staff entrance to each site there is a poster showing the required PPE and a tour of the site will show if PPE is generally being adhered to as required.
9.1 During your tour of the site is general uniform dress code being complied with (uniform including top and trousers)?
9.2 Are ALL staff (not in offices) wearing the required Bump Hat?
9.3 Are all staff (not in offices) wearing appropriate, reinforced toe and anti-slip, safety shoes?
9.4 Are all staff (in production areas) wearing ear protection?
9.5 Is there clear signage on entry to production (from main entrance and warehouses etc) that HEARING PROTECTION MUST BE WORN?
9.6 Is there clear signage on entry to yard or warehouse (where FLTs operate) that HEARING PROTECTION MUST BE REMOVED?
9.7 Are Hi-Viz jackets available for entry to the warehouse/yard areas?
9.8 Are people seen wearing the necessary Hi-Viz jackets when in the warehouse/yard areas?
9.9 Safety glasses / eye protection should be worn by staff when using aerosol cleaners etc. Is this the case on this site tour?
9.10 Specific PPE is required for purging and these are on Purging PPE boards in the production area. Do the purging PPE boards have all the necessary equipment (visor, heat resistant gloves; gauntlets; and purging bar)?
9.11 Is the necessary purging PPE being used by staff during purging of the machine?
9.12 Specific PPE is required for working with granulators and these are on Granulator PPE boards where there is a granulator in use. Do the granulator PPE boards have ALL the necessary equipment available? (Kevlar gloves with extra plastic protection to back of hand; safety glasses; and suitable bar for blade movement)?

Element 15: Control of Hazardous Substances

The site has an emergency plan (Business Continuity Plan) to manage emergency situations. There are also regular Fire Assessments and inspections to ensure remedial actions are taken where necessary to be prepared for an emergency situations.
The site will use a wide variety of substances (for cleaning, lubricating etc) and these substances need to be stored correctly and assessed as being safe for use, with necessary controls provided.
15.1 During a tour of the site select three chemicals or substances (aerosols, cans, tins of liquid, solids in tins etc) and make a note of the substance (a photo). Check these substances are on the COSHH list available on the site hub screen. Are they in date (should be reviewed every year)?
15.2 Substances should be stored in their correct cabinets or within toolboxes. Are all substances stored correctly (not on machines or scattered around various areas of the site)?

PART 4: Elements 4 and 16

Element 4: Risk Management and Higher Risk Tasks

All Risk Assessments are available on the hub screen at each site. A log of all Risk Assessments is available by consulting with the Operations Manager or EHS Manager. There are two different types of Risk Assessment on site.
1/. Machine Risk Assessments: At minimum these will be a PUWER (checklist) Risk Assessment which should be complete every 3 years (or sooner if equipment has been moved or changed). The PUWER may also be supported by a specific MACHINE / EQUIPMENT Risk Assessment (these are being developed across all sites.
2/. Activity Risk Assessments: Risk Assessments have been developed for all recognised activities on site. These are completed by the following sections: Office/Admin; Quality Control; Production; Technical; Warehouse activities. Activity Risk Assessments must be reviewed every 3 years (or earlier if a significant change or incident occurs).
4.1 ALL Risk Assessments: Check the Risk Assessment Log for the site (Operations Manager). Use the slider to indicate the percentage of Risk Assessments that are within date for the site. Scale: 1= 10% up to 10 = 100%.
4.2 Machine/Equipment Risk Assessments: Select any THREE machines on site (IMMs; or Assemblers; or Wadders; or a mix).

Machine Risk Assessments

a. Confirm Machine type (IMM, Wadder, Assembler etc):
b. Confirm Machine number (bay position):
c. Confirm Machine serial number:
d. Is there a PUWER Risk Assessment for this machine?
e. Is there a MACHINE / EQUIPMENT Risk Assessment for this machine?
f. • Are all the open actions (if any) shown on the Risk Assessment within date?
4.3 Activity Risk Assessments: Select three ACTIVITY Risk Assessments.

Activity Risk Assessments

a. Activity Risk Assessment Name:
b. Activity Risk Assessment Area (Office/QC/Prdn etc):
c. Has this Risk Assessment been reviewed in the last 3 years.
d. Are all the open actions (if any) shown on the Risk Assessment within date?
4.4 Check the bottom right corner of ANY of the activity Risk Assessments. Are there office/QC/production/warehouse/technical staff included on the Risk Assessment document?
The outcome of Risk Assessments will often be the requirement for a Safe Working Procedure (SWP) or Work Instruction (WI). SWPs are safety specific and required for higher risk tasks. WI will be for other, less safety critical activities, but will have information regarding specific safety aspects. All SWPs and WIs should be available to all on the site hub screen.
4.5 Check the site hub screen. Is there access to all Work Instructions?
4.6 Select a SWP (see site hub screen). Select a staff member who performs this task. Do they have up to date training for this activity? (You will need to ask the Factory Manager or Supervisor to check the training matrix).
4.7 Ask to see the site dynamic Risk Assessments (speak to Production Manager or Operations Manager or Factory Manager). Has there been a dynamic Risk Assessment logged in the last 2 months?
Certain activities have higher risks and therefore need higher level controls. These activities are: Lifting Operations (Crane use); Working at Height; Hot Work; Working in Confined Spaces).
4.8 Cranes – Lifting: Check SWP 8.30 and SWP 8.31 (site hub screen). Are these SWP within the review date (within 3 years since last review or creation)?
4.9 Cranes – Lifting: Check the lifting colour coding for the site (Zurich). What colour should all equipment be marked with?
4.10 Cranes – Lifting: Check 3 parts of lifting equipment. Does their colour match the required colour coding?
4.11 Working at Height: Check SWP 8.28 (site hub screen). Is this SWP within the review date (within 3 years since last review or creation)?
4.12 Check 2 sets of steps on site. Have they had their checks completed within the required period (minimum monthly)?
4.13 Check any fixed access ladders (sprinklers access, silo access, roof access etc). Do these fixed access ladders have a locked access guard in place?
Certain activities have higher risks and therefore need higher level controls. These may require specific permits to work. These specific work permits are: The site will have a set of specific work permits for: Work at Height; Confined space entry; Hot work; Electrical Work.
4.14 Ask to see the most recent specific work permit.
4.14.a. What work was this specific permit needed for?
4.14.b. What date was this permit valid on?

Element 16: Contractor Safety

Contractors working on site must be controlled. This is usually done by assessing the risk their activity presents, issuing any necessary work permits, ensuring they are properly trained and prepared for the task, and manging during their activity while on site.
16.1 Check the approved contractors list which is usually held in the Front Office (may be fully electronic). Are approximately 90% (or more) of the contractors on the list within the necessary approval date (insurance certificate is within date)?
16.2 The approved contractors list will also show if they have completed the contractor C12 assessment. Have 80% or more completed the C12 assessment?
16.3 If there are contractors working on site at the time of the audit do they have the necessary General Work Permit?
16.4 Work permits should only be valid for a single day. Are Work Permits from previous days all signed off correctly?
16.5 If there are contractors working on site at the time of the audit have they completed the necessary Contractor Site Induction (should have been completed within the last 12 months)?

PART 5: Elements 11 -17 - 19 - 20

Element 11: Equipment Inspections and Preventative Maintenance

All sites will have both internal and external inspections of equipment. The internal inspections will be part of a schedule held by the Operations Manager; and equipment around the site will have checks fitted to them which must be up to date. The external inspections will be completed by external companies and will have actions shown to ensure compliance.
11.1 Internal Inspections: Does the site (Operations Manager) have an up-to-date schedule of all internal inspections for machines and equipment?
11.2 Internal Inspections: Check several sets of portable steps on site. Are the inspections for these up to date (maximum one month old)?
11.4 Internal Inspections: Check one electric Powered Pallet Truck on site. Are the inspections for this PPT within date (should be checked daily)?
11.5 Internal Inspections: Check a set of racking in the warehouse. Are the inspections for these up to date (maximum one month old)?

Element 17: Ergonomics

The site will have an ergonomic risk assessment program. This will include elements of manual handling, Display Screen Equipment (DSE) assessments and continuous improvement through ergonomic improvement projects.
17.1 Palletised polymer material has to be loaded manually into the day bins / internal silos on site. A vacuum hover-lift is provided to assist with this task. Is the hover-lift being used for this task?
17. 2 Observe staff lifting/carrying/moving items within production/warehouse. Are correct manual handling techniques being followed?

Element 19: Workplace Transport and Vehicle Safety

Transport (FLTs etc) in the workplace represent a significant hazard and therefore risk that needs to be controlled. This is done through Risk Assessment and practical controls in Workplace Transport areas.
19.1 Check the site hub screen and open two or more of the TRANSPORT Risk Assessments. Are they within review date (should be reviewed every 3 years)?
19.2 Are all actions on the TRANSPORT Risk Assessments completed or still within their due period?
19.3 External Transport: Is there good, fully working lighting in car parks and yards?
19.4 External Transport: Is the surface in the yard areas in good condition?
19.5 External Transport: Are all markings in yard areas clear and in good condition?
19.6 External Transport: Is there a designated walkway in the yard for pedestrians?
19.7 External Transport: If there are lorries being loaded has the driver given his keys to the warehouse person during loading?
19.8 External Transport: Is there a designated walkway in the car park for pedestrians?
19.9 External Transport: Are the designated walkways seen to be in use during your inspections?
19.10 Internal Transport: Are forklift trucks (FLTs) restricted from entering production area?
19.11 Internal Transport: Is the corral barrier (separating pedestrians for FLT traffic in warehouse in good, working condition?
19.12 Internal Transport: Is the corral barriers seen to be in use during your inspection?
19.13 Internal Transport: Is there good, working lights in the warehouse areas?
19.14 Internal Transport: Is floor surface in the warehouse in visibly good condition?
19.15 Internal Transport: Are blind spots (end of aisles etc) in the warehouse covered by mirrors (possibly above head level)?
19.16 Internal Transport: Are all people seen in the warehouse wearing correct PPE? (Check that ear protection is NOT being used, safety shoes being worn, and Hi-Vis jackets are being worn)?
19.17 Fork Lift Trucks: Are FLTs being driven with due care for possible pedestrians (driven slowly; use of horn; lights working; are they aware of pedestrians/you)?
19.18 Fork Lift Trucks: Check a FLT on site and ask the driver to show you the safety checks for the day. Have they been completed?
19.19 Fork Lift Trucks: Is the blue light on the FLT (at rear) working correctly (should sign on the floor to alert pedestrians to FLT movement)?
19.20 Fork Lift Trucks: Is the FLT driver wearing the Safety Belt when driving?

Element 20: Environmental

The site has responsibilities to control the effects the site activities may have on the environment. Many of these are assessments etc that can not be inspected. Therefore this section focus is on one significant element – Operation Clean Sweep OCS® and control of pellet loss. OCS® audits are conducted once every quarter (Oct – Dec; Jan-Mar; Apr-Jun; Jul-Sep).
20.1 Check the i-audit record for the site (speak to Operations Manager/Factory Manager or EHS Manager). Has the OCS® audit been completed for the last quarter?
20.2 Do external silo areas have OCS® signage to inform drivers delivering materials of the requirements for the site?
20.3 Is their equipment to clear spills of granules quickly if found? (These can be yard housekeeping kits or kits on-board FLTs).
20.4 Is the yard clear of significant pellet spills (if any are found please ensure they are cleared immediately)?
20.5 Are drain covers fitted to all drains in the yard to collect pellets and stop them entering the surface water drains. (Check deep inside as most are fitted underneath the main drain gate)?
20.6 Is there a collection bucket available at external silos to be used by drivers/warehouse when coupling and uncoupling bulk silo delivery pipes?

PART 6: Elements 12 & 13

Element 12: Hazardous Energy Control

There are different forms of Hazardous Energy around the site(s) that needs to be controlled when conducting specific tasks. Hazardous energy is controlled through Lock Out Tag Out (LOTO) procedures or through identification on Minor Intervention controls (such as interlocked guards etc).
12.1 Check the site hub screen. Is the SWP 8.17 Lockout Procedure available to view by all staff?
12.2 Select a member of the Technical staff. Record their name.
12.3 Does the Technical staff member have their own LOTO kit?
12.4 Has the Technical staff member been trained? Ask them.
12.5 If there is a staff member carrying out a LOTO activity during your inspection?
- NO. There is no LOTO activity happening
- YES. LOTO activity is happening
12.5.a. Is there a LOTO Map on the machine?
12.5.b. Is the team member able to identify the hazardous energy involved in the task being done? Ask them.
12.5.c. Has the correct equipment been used to LOTO the equipment for this task?
12.6. Inspect random machines from two different rows of Injection Moulding machines on site. Are there LOTO Maps shown on each Injection Moulding Machine? (usually found near where M/C Safety checks folders are held)
12.7 During your inspection, did you see a machine or any equipment that was LOTO?
- Yes, there is a machine that is LOTO.
- No, there is not machine that is LOTO.
12.7.a Is the machine / equipment correctly LOTO? (There should be an identified padlock through correct hazardous energy source and correctly logged on LOTO board or LOTO Register).
12.10.b Check the LOTO board and/or register. Are there any machines / equipment shown as LOTO?
12.10. Has the correct equipment been used to LOTO the equipment for this task? (There should be an identified padlock through correct hazardous energy source).
12.8 LOTO Granulators: Check the Bulk granulator on site. Does it have a LOTO Map label applied?
12.9. LOTO Granulators: Check several (if applicable) in-line / under machine granulators. Do they have LOTO Map label applied?
12.10 Has a LOTO padlock been fitted to any machines on site where fixed guards (not opening guard doors) have been removed? Mark N/A if not there are no machines with guards removed.
12.11 Minor Interventions: Check with the EHS Manager what the current Minor Interventions project list. Is this list 90% complete for the site?
12.12 Minor Interventions: Check several machines. Do they have working interlocks on the guard doors?
12.13 LOTO (Electrical): Check ten electrical cabinets (on minimum five individual machines). Are all electrical cabinets locked closed with either a key lock or a padlock and hasp?
12.14 LOTO (Electrical): Do electrical cabinets have appropriate warning signs?

Element 13: Machinery Guarding

Machines and equipment may have both fixed and non-fixed guards to protect from hazards. Fixed guards should be screwed/bolted securely. Non-fixed guards could be doors etc with suitable interlocks (equipment will stop safely if a door is opened).
13.1 Fixed Guards: Inspect minimum five machines (IMMs and assembly machines). Note the machines inspected. Select YES if all guards are correct. Select NO if there are there any missing or removed fixed guards on machines that have NOT been LOTO?
13.2 Fixed Guards: Select YES if all guards are correct. Select NO if there are there any damaged fixed guards on the machines inspected?
13.3 Fixed Guards: Select YES if all guards are correct. Select NO if there are there any missing or badly damaged screws/bolts in fixed guards on the machines inspected?
13.4 On the five machines inspected are all the Emergency stops in visibly good condition (not broken or missing from their position)?
13.5 On the IMMs inspected are they all fitted with barrel protection (insulation)?
13.6 Is there appropriate signage at the IMM barrel to show Hot Surfaces?
13.7 Is there restriction to access to the well of the IMMs (at low level) and is it securely fitted?
13.8 Non-Fixed Guards: Select three random machines (at least one not an IMM). Note the machines inspected. Are all interlocks on guard doors in visibly good condition (not broken etc)?
13.9 Non-Fixed Guards: With help from an operator or technician (if needed) open a guard door – does the equipment stop quickly and safely?
13.10 Fixed and Non-Fixed Guards: IMMs will have a daily safety check sheet. Check the daily safety check sheets on five IMMs. Are all checks completed as required (daily)?
13.11 Fixed and Non-Fixed Guards: Assembly and Granulator equipment will have a weekly safety check sheet. Check the weekly safety check sheets on five assemblers/granulators/wadders. Are all checks completed as required (weekly)?
13.12 The engineering bay has restricted access through electronic door locks. Is the electronic door lock on the engineering bay working correctly?
13.13 The tool room (where applicable) has restricted access through electronic door locks. Is the electronic door lock on the toolroom working correctly?
13.14 Check pedestal/pillar drill in the engineering bay or toolroom. Does it have a guard fitted in place at the working part of the drill?
13.15 Is there an authorised user list with appropriate signage at the position of the pedestal/pillar drill?
13.16 Granulator Safety: Are SWPs 8.01, 8.02, 8.03 and 8.04 (all for the Bulk Granulator) available in a folder at the Bulk Granulator?
13.17 Granulator Safety: Are all the Emergency stops in visibly good condition (not broken or missing from their position)?
13.18 Granulator Safety: Are all guards on the Bulk Granulator in visibly good condition?
13.19 Is the blade restraint (Pac-Man) fitted to the Bulk Granulator?

PART 1: Elements 1 - 2 - 3 - 10 - 18

Element 1: Leadership and Accountability

The site leadership team should be working to agreed standards, policies and with plans and objectives for continuous improvement. Policies, responsibilities, plans and objectives should be displayed and communicated to all on site.
1.1 Is the EHS Policy displayed on site for both staff and visitors?
1.2 Are the Berry EHS Principles displayed on entry to and around the site?
1.3 Are the EHS responsibilities shown on notice boards or flip folders on site?
1.4 Is the site EHS Scorecard displayed on the noticeboard, and does it show the most recent full month data?

Element 2: Employee Engagement and Behavioural Safety

The business should be engaging with all staff to communicate EHS issues and obtain feedback and ideas for possible improvement. This is done through regular inspections, Factory Meetings and RoES meetings. These should be recorded.
2.1 Ask to see the latest Factory Meeting minutes (Operations Manager). Are they being completed every month?
2.2 Ask EHS Manager for copy of RoES (Representatives of Employee Safety) meeting minutes. Are actions listed and being progressed?

Element 3: Regulatory Compliance

The business is subject to all the national (and international) regulations and legislation that applies to a manufacturing business. These regulations should be known and reviewed in a regulation review system. This is managed by the EHS Manager and for this section of the inspection you will need to discuss this with the EHS Manager.
3.1 Ask the EHS Manager to show you the Regulations Legislation review system.
3.2 Are actions in place for any non-compliant areas?
3.3 Check two or three actions. Are these actions all completed on target date?

Element 10: Management of Change

In its most basic form, a Management of Change (MoC) system simply ensures that a risk assessment is carried out before a change is made to anything. This could be a change to a product, material, equipment or someone’s job. We must make sure that, for any changes that may affect our health and safety, we follow a system that ensures we record the change, do a formal risk assessment and manage the actions that are required to make sure the change does not increase the risk of an accident. To inspect this element you will need to talk with the EHS Manager.
10.1 What Management of Change projects are listed for the site? Please list them:
10.2 Select a MoC project. Are all the actions within required date?

Element 18: Health and Wellness

As well as general safety, the company has a duty of care for the heath and wellness generally of all employees. This includes provision of First Aid and suitable equipment and facilities.
18.1 Is there a list of trained First Aiders shown throughout the site?
18.2 Check two or three items from a selected First Aid kit. Are they each within their expiry date?
18.3 Noise: Is there signage on entry to production areas that hearing protection must be worn?
18.4 Noise: Are all employees wearing hearing protection in production?
18.5 Noise: Is there signage on entry to yard/warehouse areas to instruct people that hearing protection should be removed.

PART 2: Elements 6 - 8 - 14

Element 6: Corrective and Preventative Actions

Where issues are found or feedback is received, the site needs to formally record any actions required. These Corrective and Preventative Actions (CAPAs) should be formally recorded and have timescales to complete.
6.1 Check the site EHS Scorecard (site EHS board). Does this show the percentage of hazards resolved (Hazard Resolution) for the month at 90% or more?
6.2 Does the Scorecard show the percentage of hazards resolved (Hazard Resolution) for rolling 12 months (small chart) at 90%?
6.3 Do the Hazard Metrics on the Scorecard show number of hazards reported per person at the required level of 6 per person per year? (Note: This pro rate. E.g. if 3 months through the Oct-Sep year divide the number by 3 and multiply by 12 to give full year rate).
6.4 Check the site EHS Scorecard (site EHS board). Does this show Risk Management for FM Global as Blue?
6.5 Ask the Factory Manager to show you the oldest open hazard. Is there an action plan (with date) for closing this open hazard?

Element 8: Training and Communications

The training at all sites is recorded using the Mitrefinch TMS system. All Factory Managers and Supervisors have access to TMS and can provide a training matrix by department to show who is trained in what activities. For this inspection you will need to speak with the Factory Managers / Supervisors to review the training matrix.
8.1 Check the training matrix for Operators (Day or Night Shift). Is all the training approximately 90% up to date or scheduled to be up to date? (out of date will show as red on the matrix).
8.2 Production Staff: Is Induction Training shown as completed for all staff?
8.3 Production Staff: Is Manual Handling training shown as completed and within date for all staff?
8.4 Production Staff: IS SWP 8.34 training up to date for all production staff?
8.5 Check the training matrix for Technical. Is all the training approximately 90% up to date or scheduled to be up to date? (out of date will show as red on the matrix).
8.6 Technical: Is SWP 8.33 training up to date for all Technical staff?
8.7 Ask who changes the blades on the bulk granulator. Record their name. Is SWP 8.04 training up to date for this person?
8.8 Check the training matrix for Warehouse. Is all the training approximately 90% up to date or scheduled to be up to date? (out of date will show as red on the matrix).
8.9 Warehouse: Is SWP 8.08 training up to date for all Warehouse staff?
8.10 Warehouse: Is SWP 8.36 training up to date for all Warehouse staff?
8.11 Check the pillar/pedestal drill in the engineering bay. Select one person from the authorised user list. Is this person’s training for SWP 8.38 up to date in the training matrix?
8.12 Communications: Are the RoES Safety Group members shown on the EHS noticeboard?
8.13 Communications: Are there any First Alert notices shown on the EHS noticeboard?
8.14 Communications: Are the Top 10 Risk projects shown on the noticeboard and are they up to date (oldest should be previous month)?
8.15 Communications: Are the information screens working on site?
8.16 Ask a staff member if they know the days since last recordable accident on site (this is displayed on board outside the entrance to the site)?

Element 14: Emergency Preparedness and Fire Prevention

The site has an emergency plan (Business Continuity Plan) to manage emergency situations. There are also regular Fire Assessments and inspections to ensure remedial actions are taken where necessary to be prepared for an emergency situations.
14.1 Speak with the Operations Manager and ask to see the latest version of the Business Continuity Plan. Check with the Quality Manager – is this the correct date and version of the Business Continuity Plan?
14.2 Fire: Check with the Operations Manager or the Factory Manager for the latest copy of the annual Fire Risk Assessment. Is this in date (should be within one year)?
14.3 Fire: Have actions shown on the Fire Risk Assessment been completed/in progress?
14.4 Fire: Check with the Factory manager when the most recent Fire Drill was completed. Was it done within the last 6 months?
14.5 Fire (Yard Area): Check the yard areas. Are all pallets etc stored away from the building to prevent risk of fire?
14.6 Fire (FLT Charging Area). Check the FLT charging areas. Is it free from wooden pallets, debris and other flammable items?

PART 3: Elements 7 - 9 - 15

Element 7: Housekeeping and 5S

A site with well maintained housekeeping will inherently be a safer environment for all to work in. This section of the inspection will assess: the general standard of housekeeping; the progress being made on the 5S projects around the site; and records of housekeeping to ensure standards are being met.
7.1 General: Are walkways in production clearly marked and uncluttered? (Pallets, cartons, equipment etc).
7.2 General: Are walkways in production free of debris that could cause slips such as oil, granules, spilled caps etc?
7.3 Ask to see a weekly Managers/Supervisors 15-minute recorded inspection for the previous week. Has this been completed?
7.4 Check the cleaning records for the Production area. Are these completed and up to date?
7.5 Are the Housekeeping boards accessible and do they contain all necessary equipment?
7.6 Use the slider to score the production area housekeeping between 0 (Poor) and 10 (Good).
7.7 Check the cleaning records for the Engineering bay/room. Are these completed and up to date?
7.8 Use the slider to score the Engineering bay/room housekeeping between 0 (Poor) and 10 (Good).
7.9 If applicable, check the cleaning records for the Toolroom. Are these completed and up to date?
7.10 Use the slider to score the Toolroom area housekeeping between 0 (Poor) and 10 (Good).
7.11 Check the cleaning records for the Warehouse / Yard areas. Are these completed and up to date?
7.12 Are pallets stacked safely and stored at least 10 metres (or other required distance) away from buildings?
7.13 Use the slider to score the warehouse / yard housekeeping between 0 (Poor) and 10 (Good).
7.14 5S: The sites are implementing a specific 5S system and this will be at various stages in different areas of the site. Is there a 5S information board on site?
What stage is the site at on its 5S journey? List: SORT – SET – SHINE – STANDARDISE – SUSTAIN ?
Check within a 5S area of the site. Are all equipment, parts, cartons, pallets etc. in their correctly identified areas?

Element 9: Personal Protective Equipment

Personal Protective Equipment (PPE)is issued to all staff according to the activities they will be engaged in. PPE can include: Hats; gloves (various types); shoes; Hi-Viz vests/coats; masks; safety glasses; visors; general uniform; ear protection). At the staff entrance to each site there is a poster showing the required PPE and a tour of the site will show if PPE is generally being adhered to as required.
9.1 During your tour of the site is general uniform dress code being complied with (uniform including top and trousers)?
9.2 Are ALL staff (not in offices) wearing the required Bump Hat?
9.3 Are all staff (not in offices) wearing appropriate, reinforced toe and anti-slip, safety shoes?
9.4 Are all staff (in production areas) wearing ear protection?
9.5 Is there clear signage on entry to production (from main entrance and warehouses etc) that HEARING PROTECTION MUST BE WORN?
9.6 Is there clear signage on entry to yard or warehouse (where FLTs operate) that HEARING PROTECTION MUST BE REMOVED?
9.7 Are Hi-Viz jackets available for entry to the warehouse/yard areas?
9.8 Are people seen wearing the necessary Hi-Viz jackets when in the warehouse/yard areas?
9.9 Safety glasses / eye protection should be worn by staff when using aerosol cleaners etc. Is this the case on this site tour?
9.10 Specific PPE is required for purging and these are on Purging PPE boards in the production area. Do the purging PPE boards have all the necessary equipment (visor, heat resistant gloves; gauntlets; and purging bar)?
9.11 Is the necessary purging PPE being used by staff during purging of the machine?
9.12 Specific PPE is required for working with granulators and these are on Granulator PPE boards where there is a granulator in use. Do the granulator PPE boards have ALL the necessary equipment available? (Kevlar gloves with extra plastic protection to back of hand; safety glasses; and suitable bar for blade movement)?

Element 15: Control of Hazardous Substances

The site has an emergency plan (Business Continuity Plan) to manage emergency situations. There are also regular Fire Assessments and inspections to ensure remedial actions are taken where necessary to be prepared for an emergency situations.
The site will use a wide variety of substances (for cleaning, lubricating etc) and these substances need to be stored correctly and assessed as being safe for use, with necessary controls provided.
15.1 During a tour of the site select three chemicals or substances (aerosols, cans, tins of liquid, solids in tins etc) and make a note of the substance (a photo). Check these substances are on the COSHH list available on the site hub screen. Are they in date (should be reviewed every year)?
15.2 Substances should be stored in their correct cabinets or within toolboxes. Are all substances stored correctly (not on machines or scattered around various areas of the site)?

PART 4: Elements 4 and 16

Element 4: Risk Management and Higher Risk Tasks

All Risk Assessments are available on the hub screen at each site. A log of all Risk Assessments is available by consulting with the Operations Manager or EHS Manager. There are two different types of Risk Assessment on site.
1/. Machine Risk Assessments: At minimum these will be a PUWER (checklist) Risk Assessment which should be complete every 3 years (or sooner if equipment has been moved or changed). The PUWER may also be supported by a specific MACHINE / EQUIPMENT Risk Assessment (these are being developed across all sites.
2/. Activity Risk Assessments: Risk Assessments have been developed for all recognised activities on site. These are completed by the following sections: Office/Admin; Quality Control; Production; Technical; Warehouse activities. Activity Risk Assessments must be reviewed every 3 years (or earlier if a significant change or incident occurs).
4.1 ALL Risk Assessments: Check the Risk Assessment Log for the site (Operations Manager). Use the slider to indicate the percentage of Risk Assessments that are within date for the site. Scale: 1= 10% up to 10 = 100%.
4.2 Machine/Equipment Risk Assessments: Select any THREE machines on site (IMMs; or Assemblers; or Wadders; or a mix).

Machine Risk Assessments

a. Confirm Machine type (IMM, Wadder, Assembler etc):
b. Confirm Machine number (bay position):
c. Confirm Machine serial number:
d. Is there a PUWER Risk Assessment for this machine?
e. Is there a MACHINE / EQUIPMENT Risk Assessment for this machine?
f. • Are all the open actions (if any) shown on the Risk Assessment within date?
4.3 Activity Risk Assessments: Select three ACTIVITY Risk Assessments.

Activity Risk Assessments

a. Activity Risk Assessment Name:
b. Activity Risk Assessment Area (Office/QC/Prdn etc):
c. Has this Risk Assessment been reviewed in the last 3 years.
d. Are all the open actions (if any) shown on the Risk Assessment within date?
4.4 Check the bottom right corner of ANY of the activity Risk Assessments. Are there office/QC/production/warehouse/technical staff included on the Risk Assessment document?
The outcome of Risk Assessments will often be the requirement for a Safe Working Procedure (SWP) or Work Instruction (WI). SWPs are safety specific and required for higher risk tasks. WI will be for other, less safety critical activities, but will have information regarding specific safety aspects. All SWPs and WIs should be available to all on the site hub screen.
4.5 Check the site hub screen. Is there access to all Work Instructions?
4.6 Select a SWP (see site hub screen). Select a staff member who performs this task. Do they have up to date training for this activity? (You will need to ask the Factory Manager or Supervisor to check the training matrix).
4.7 Ask to see the site dynamic Risk Assessments (speak to Production Manager or Operations Manager or Factory Manager). Has there been a dynamic Risk Assessment logged in the last 2 months?
Certain activities have higher risks and therefore need higher level controls. These activities are: Lifting Operations (Crane use); Working at Height; Hot Work; Working in Confined Spaces).
4.8 Cranes – Lifting: Check SWP 8.30 and SWP 8.31 (site hub screen). Are these SWP within the review date (within 3 years since last review or creation)?
4.9 Cranes – Lifting: Check the lifting colour coding for the site (Zurich). What colour should all equipment be marked with?
4.10 Cranes – Lifting: Check 3 parts of lifting equipment. Does their colour match the required colour coding?
4.11 Working at Height: Check SWP 8.28 (site hub screen). Is this SWP within the review date (within 3 years since last review or creation)?
4.12 Check 2 sets of steps on site. Have they had their checks completed within the required period (minimum monthly)?
4.13 Check any fixed access ladders (sprinklers access, silo access, roof access etc). Do these fixed access ladders have a locked access guard in place?
Certain activities have higher risks and therefore need higher level controls. These may require specific permits to work. These specific work permits are: The site will have a set of specific work permits for: Work at Height; Confined space entry; Hot work; Electrical Work.
4.14 Ask to see the most recent specific work permit.
4.14.a. What work was this specific permit needed for?
4.14.b. What date was this permit valid on?

Element 16: Contractor Safety

Contractors working on site must be controlled. This is usually done by assessing the risk their activity presents, issuing any necessary work permits, ensuring they are properly trained and prepared for the task, and manging during their activity while on site.
16.1 Check the approved contractors list which is usually held in the Front Office (may be fully electronic). Are approximately 90% (or more) of the contractors on the list within the necessary approval date (insurance certificate is within date)?
16.2 The approved contractors list will also show if they have completed the contractor C12 assessment. Have 80% or more completed the C12 assessment?
16.3 If there are contractors working on site at the time of the audit do they have the necessary General Work Permit?
16.4 Work permits should only be valid for a single day. Are Work Permits from previous days all signed off correctly?
16.5 If there are contractors working on site at the time of the audit have they completed the necessary Contractor Site Induction (should have been completed within the last 12 months)?

PART 5: Elements 11 -17 - 19 - 20

Element 11: Equipment Inspections and Preventative Maintenance

All sites will have both internal and external inspections of equipment. The internal inspections will be part of a schedule held by the Operations Manager; and equipment around the site will have checks fitted to them which must be up to date. The external inspections will be completed by external companies and will have actions shown to ensure compliance.
11.1 Internal Inspections: Does the site (Operations Manager) have an up-to-date schedule of all internal inspections for machines and equipment?
11.2 Internal Inspections: Check several sets of portable steps on site. Are the inspections for these up to date (maximum one month old)?
11.4 Internal Inspections: Check one electric Powered Pallet Truck on site. Are the inspections for this PPT within date (should be checked daily)?
11.5 Internal Inspections: Check a set of racking in the warehouse. Are the inspections for these up to date (maximum one month old)?

Element 17: Ergonomics

The site will have an ergonomic risk assessment program. This will include elements of manual handling, Display Screen Equipment (DSE) assessments and continuous improvement through ergonomic improvement projects.
17.1 Palletised polymer material has to be loaded manually into the day bins / internal silos on site. A vacuum hover-lift is provided to assist with this task. Is the hover-lift being used for this task?
17. 2 Observe staff lifting/carrying/moving items within production/warehouse. Are correct manual handling techniques being followed?

Element 19: Workplace Transport and Vehicle Safety

Transport (FLTs etc) in the workplace represent a significant hazard and therefore risk that needs to be controlled. This is done through Risk Assessment and practical controls in Workplace Transport areas.
19.1 Check the site hub screen and open two or more of the TRANSPORT Risk Assessments. Are they within review date (should be reviewed every 3 years)?
19.2 Are all actions on the TRANSPORT Risk Assessments completed or still within their due period?
19.3 External Transport: Is there good, fully working lighting in car parks and yards?
19.4 External Transport: Is the surface in the yard areas in good condition?
19.5 External Transport: Are all markings in yard areas clear and in good condition?
19.6 External Transport: Is there a designated walkway in the yard for pedestrians?
19.7 External Transport: If there are lorries being loaded has the driver given his keys to the warehouse person during loading?
19.8 External Transport: Is there a designated walkway in the car park for pedestrians?
19.9 External Transport: Are the designated walkways seen to be in use during your inspections?
19.10 Internal Transport: Are forklift trucks (FLTs) restricted from entering production area?
19.11 Internal Transport: Is the corral barrier (separating pedestrians for FLT traffic in warehouse in good, working condition?
19.12 Internal Transport: Is the corral barriers seen to be in use during your inspection?
19.13 Internal Transport: Is there good, working lights in the warehouse areas?
19.14 Internal Transport: Is floor surface in the warehouse in visibly good condition?
19.15 Internal Transport: Are blind spots (end of aisles etc) in the warehouse covered by mirrors (possibly above head level)?
19.16 Internal Transport: Are all people seen in the warehouse wearing correct PPE? (Check that ear protection is NOT being used, safety shoes being worn, and Hi-Vis jackets are being worn)?
19.17 Fork Lift Trucks: Are FLTs being driven with due care for possible pedestrians (driven slowly; use of horn; lights working; are they aware of pedestrians/you)?
19.18 Fork Lift Trucks: Check a FLT on site and ask the driver to show you the safety checks for the day. Have they been completed?
19.19 Fork Lift Trucks: Is the blue light on the FLT (at rear) working correctly (should sign on the floor to alert pedestrians to FLT movement)?
19.20 Fork Lift Trucks: Is the FLT driver wearing the Safety Belt when driving?

Element 20: Environmental

The site has responsibilities to control the effects the site activities may have on the environment. Many of these are assessments etc that can not be inspected. Therefore this section focus is on one significant element – Operation Clean Sweep OCS® and control of pellet loss. OCS® audits are conducted once every quarter (Oct – Dec; Jan-Mar; Apr-Jun; Jul-Sep).
20.1 Check the i-audit record for the site (speak to Operations Manager/Factory Manager or EHS Manager). Has the OCS® audit been completed for the last quarter?
20.2 Do external silo areas have OCS® signage to inform drivers delivering materials of the requirements for the site?
20.3 Is their equipment to clear spills of granules quickly if found? (These can be yard housekeeping kits or kits on-board FLTs).
20.4 Is the yard clear of significant pellet spills (if any are found please ensure they are cleared immediately)?
20.5 Are drain covers fitted to all drains in the yard to collect pellets and stop them entering the surface water drains. (Check deep inside as most are fitted underneath the main drain gate)?
20.6 Is there a collection bucket available at external silos to be used by drivers/warehouse when coupling and uncoupling bulk silo delivery pipes?

PART 6: Elements 12 & 13

Element 12: Hazardous Energy Control

There are different forms of Hazardous Energy around the site(s) that needs to be controlled when conducting specific tasks. Hazardous energy is controlled through Lock Out Tag Out (LOTO) procedures or through identification on Minor Intervention controls (such as interlocked guards etc).
12.1 Check the site hub screen. Is the SWP 8.17 Lockout Procedure available to view by all staff?
12.2 Select a member of the Technical staff. Record their name.
12.3 Does the Technical staff member have their own LOTO kit?
12.4 Has the Technical staff member been trained? Ask them.
12.5 If there is a staff member carrying out a LOTO activity during your inspection?
- NO. There is no LOTO activity happening
- YES. LOTO activity is happening
12.5.a. Is there a LOTO Map on the machine?
12.5.b. Is the team member able to identify the hazardous energy involved in the task being done? Ask them.
12.5.c. Has the correct equipment been used to LOTO the equipment for this task?
12.6. Inspect random machines from two different rows of Injection Moulding machines on site. Are there LOTO Maps shown on each Injection Moulding Machine? (usually found near where M/C Safety checks folders are held)
12.7 During your inspection, did you see a machine or any equipment that was LOTO?
- Yes, there is a machine that is LOTO.
- No, there is not machine that is LOTO.
12.7.a Is the machine / equipment correctly LOTO? (There should be an identified padlock through correct hazardous energy source and correctly logged on LOTO board or LOTO Register).
12.10.b Check the LOTO board and/or register. Are there any machines / equipment shown as LOTO?
12.10. Has the correct equipment been used to LOTO the equipment for this task? (There should be an identified padlock through correct hazardous energy source).
12.8 LOTO Granulators: Check the Bulk granulator on site. Does it have a LOTO Map label applied?
12.9. LOTO Granulators: Check several (if applicable) in-line / under machine granulators. Do they have LOTO Map label applied?
12.10 Has a LOTO padlock been fitted to any machines on site where fixed guards (not opening guard doors) have been removed? Mark N/A if not there are no machines with guards removed.
12.11 Minor Interventions: Check with the EHS Manager what the current Minor Interventions project list. Is this list 90% complete for the site?
12.12 Minor Interventions: Check several machines. Do they have working interlocks on the guard doors?
12.13 LOTO (Electrical): Check ten electrical cabinets (on minimum five individual machines). Are all electrical cabinets locked closed with either a key lock or a padlock and hasp?
12.14 LOTO (Electrical): Do electrical cabinets have appropriate warning signs?

Element 13: Machinery Guarding

Machines and equipment may have both fixed and non-fixed guards to protect from hazards. Fixed guards should be screwed/bolted securely. Non-fixed guards could be doors etc with suitable interlocks (equipment will stop safely if a door is opened).
13.1 Fixed Guards: Inspect minimum five machines (IMMs and assembly machines). Note the machines inspected. Are there any missing or removed fixed guards on machines that have NOT been LOTO?
13.2 Fixed Guards: Are there any damaged fixed guards on the machines inspected?
13.3 Fixed Guards: Are there any missing or badly damaged screws/bolts in fixed guards on the machines inspected?
13.4 On the five machines inspected are all the Emergency stops in visibly good condition (not broken or missing from their position)?
13.5 On the IMMs inspected are they all fitted with barrel protection (insulation)?
13.6 Is there appropriate signage at the IMM barrel to show Hot Surfaces?
13.7 Is there restriction to access to the well of the IMMs (at low level) and is it securely fitted?
13.8 Non-Fixed Guards: Select three random machines (at least one not an IMM). Note the machines inspected. Are all interlocks on guard doors in visibly good condition (not broken etc)?
13.9 Non-Fixed Guards: With help from an operator or technician (if needed) open a guard door – does the equipment stop quickly and safely?
13.10 Fixed and Non-Fixed Guards: IMMs will have a daily safety check sheet. Check the daily safety check sheets on five IMMs. Are all checks completed as required (daily)?
13.11 Fixed and Non-Fixed Guards: Assembly and Granulator equipment will have a weekly safety check sheet. Check the weekly safety check sheets on five assemblers/granulators/wadders. Are all checks completed as required (weekly)?
13.12 The engineering bay has restricted access through electronic door locks. Is the electronic door lock on the engineering bay working correctly?
13.13 The tool room (where applicable) has restricted access through electronic door locks. Is the electronic door lock on the toolroom working correctly?
13.14 Check pedestal/pillar drill in the engineering bay or toolroom. Does it have a guard fitted in place at the working part of the drill?
13.15 Is there an authorised user list with appropriate signage at the position of the pedestal/pillar drill?
13.16 Granulator Safety: Are SWPs 8.01, 8.02, 8.03 and 8.04 (all for the Bulk Granulator) available in a folder at the Bulk Granulator?
13.17 Granulator Safety: Are all the Emergency stops in visibly good condition (not broken or missing from their position)?
13.18 Granulator Safety: Are all guards on the Bulk Granulator in visibly good condition?
13.19 Is the blade restraint (Pac-Man) fitted to the Bulk Granulator?

Good Practices and Improvement Areas

Describe any good practices seen during your inspection.
Describe any required improvement areas seen during your inspection.

EHS Leadership Tour Conversation

Driving and improving safety behaviors is an important part of developing a good safety culture on site. It is important for senior management to engage with staff, using positive safety conversations, to obtain feedback and enable safety improvements. Please take the opportunity of this inspection tour to engage with at least one member of staff and record what was discussed and any actions as an outcome.
Engage with an employee and record below:
What area was the employee working?
- Production
- Warehouse
- Quality
- Technical - Engineering - Toolroom
- Office
- Contractor
- First Aider
- Other (please describe)
Name of person:
Subject(s) of conversation:
Any actions required from this conversation? (please list and add as an action):
Examples of useful questions that can be asked can be found below:
Operations (Production/Warehouse etc) Employee Questions (examples)
Office Worker Questions (examples)
Contractor Questions (examples)
First Aider (or recently injured) Questions (examples).
Name of person:
Subject(s) of conversation:
Any actions required from this conversation? (please list and add as an action):
Examples of useful questions that can be asked: can be found in the appendix section at the end of this audit.
Name of person:
Subject(s) of conversation:
Any actions required from this conversation? (please list and add as an action):
Examples of useful questions that can be asked: can be found in the appendix section at the end of this audit.
Name of person:
Subject(s) of conversation:
Any actions required from this conversation? (please list and add as an action):
Examples of useful questions that can be asked: can be found in the appendix section at the end of this audit.
Name of person:
Subject(s) of conversation:
Any actions required from this conversation? (please list and add as an action):
Examples of useful questions that can be asked: can be found in the appendix section at the end of this audit.
Name of person:
Subject(s) of conversation:
Any actions required from this conversation? (please list and add as an action):
Examples of useful questions that can be asked: can be found in the appendix section at the end of this audit.
Name of person:
Subject(s) of conversation:
Any actions required from this conversation? (please list and add as an action):
Examples of useful questions that can be asked: can be found in the appendix section at the end of this audit.
Area where person works or reason to be on site?
Name of person:
Subject(s) of conversation:
Any actions required from this conversation? (please list and add as an action):
Examples of useful questions that can be asked: can be found in the appendix section at the end of this audit.

Berry Blue Element - Leaders Inspection - Berry SCUK

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PART 1: Elements 1 - 2 - 3 - 10 - 18

Element 1: Leadership and Accountability

Element 2: Employee Engagement and Behavioural Safety

Element 3: Regulatory Compliance

Element 10: Management of Change

Element 18: Health and Wellness

PART 2: Elements 6 - 8 - 14

Element 6: Corrective and Preventative Actions

Element 8: Training and Communications

Element 14: Emergency Preparedness and Fire Prevention

PART 3: Elements 7 - 9 - 15

Element 7: Housekeeping and 5S

Element 9: Personal Protective Equipment

Element 15: Control of Hazardous Substances

PART 4: Elements 4 and 16

Element 4: Risk Management and Higher Risk Tasks

Machine Risk Assessments

Activity Risk Assessments

Element 16: Contractor Safety

PART 5: Elements 11 -17 - 19 - 20

Element 11: Equipment Inspections and Preventative Maintenance

Element 17: Ergonomics

Element 19: Workplace Transport and Vehicle Safety

Element 20: Environmental

PART 6: Elements 12 & 13

Element 12: Hazardous Energy Control

Element 13: Machinery Guarding

PART 1: Elements 1 - 2 - 3 - 10 - 18

Element 1: Leadership and Accountability

Element 2: Employee Engagement and Behavioural Safety

Element 3: Regulatory Compliance

Element 10: Management of Change

Element 18: Health and Wellness

PART 2: Elements 6 - 8 - 14

Element 6: Corrective and Preventative Actions

Element 8: Training and Communications

Element 14: Emergency Preparedness and Fire Prevention

PART 3: Elements 7 - 9 - 15

Element 7: Housekeeping and 5S

Element 9: Personal Protective Equipment

Element 15: Control of Hazardous Substances

PART 4: Elements 4 and 16

Element 4: Risk Management and Higher Risk Tasks

Machine Risk Assessments

Activity Risk Assessments

Element 16: Contractor Safety

PART 5: Elements 11 -17 - 19 - 20

Element 11: Equipment Inspections and Preventative Maintenance

Element 17: Ergonomics

Element 19: Workplace Transport and Vehicle Safety

Element 20: Environmental

PART 6: Elements 12 & 13

Element 12: Hazardous Energy Control

Element 13: Machinery Guarding

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