Information
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Audit Title
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Document No.
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Client / Site
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Conducted on
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Prepared by
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Location
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Personnel
SECTION 1: Premises and Housekeeping
1.1 Building and Floors
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Obvious unrepaired damage buildings
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Unsafe condition of floors, carpets, roadways, walkways, elevated platforms
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Have these deviations have been reported.
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Corrective action taken in timely manner
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Premises divided into ares and delegated to Safety Representative/Supervisor/HSE (on plan or in writing)
1.2 Good lighting: Natural and Artificial
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Sample lights out
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Poorly lit areas
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Reporting of lights out by safety reps/supervision/HSE monthly
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Lighting survey and monitoring of light intensities
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Have been survey results and recommendations been auctioned/planned
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Safety glass or similar used in hazardous areas
1.3 Ventilation: Natural and Artificial
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Study done for ventilation problems
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Have study results and recommendations been applied.
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Confined space area are identified, study done.
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Ventilation extraction provided and maintained
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Environmental monitoring/heat stress/sampling
1.4 Plant Hygiene Facilities
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Facilities in a clean hygienic stage
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No food in unauthorized areas
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Regular monthly inspections
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Checklist used signed, monitored
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Is the problem being dealt wit
1.5 Pollution: Air, Ground, and Water
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Study to determine whether a pollution problem exists
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Have study results and recommendation been auctioned/applied
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Hazardous waste identified
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Obvious pollution/ uncontrolled fuel, oil leakage or hazardous waste
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Is the problem being dealt with
1.6 Aisles and Storage Demarcated
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Floors demarcated as per standard
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Uninformed demarcation code used
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Demarcation adhered to
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Demarcation under electrical/mechanical equipment
1.7 Good Stacking and Storage Practices
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Storage in cupboards, on shelves neat and tidy
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No stacking on top of windowsills, cabinets, etc.
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Unsafe conditions related to stacking an storage is reported and action taken
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Stacking neat, stable and controlled
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Storage in cupboards, on shelves neat and tidy
1.8 Housekeeping
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Safety rep/appointees/HSE controlling areas by reporting (good general good housekeeping)
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Under roof areas free of junk and materials
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Corrective actions
1.9 Scrap and Refuse Bins Removal System
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Scrap bins provided
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Regular controlled removal
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Separate bins for rags, oily materials, scrap, etc.
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Bin locations demarcated
1.10 Color coding: Plant and pipelines
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Uniform color coding
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Color keyboard (legend) displayed
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Knowledge of colors (own code acceptable)
SECTION 2: Mechanical, Electrical and Personnel Safeguarding
2.1 Machine/Hazardous Equipment guarding
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All hazardous moving machine/ electrical parts within normal reach completely guarded/fenced/enclosed
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All guards installed are listed,, checked and maintained
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Inspection guards/front/back/back panels
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Record of equipment issued
2.2 Lock-System and Usage "LOTO"
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Written procedure available, updated and applied
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One key, one lock, and one authorized person is applied whenever LOTO is required
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Are tags and locks being used correctly
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Are there task specific procedures available?
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Are all affected staff trained?
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Locks numbered and all use locks are recorded on permit
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All equipment can be isolated and locked (including where fuses are drawn or valves in chemicals lines, etc.
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LOTO are monitored, supervised and controlled by competent person and authorized person/LOTO station available and well arranged.
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Do field activities match SEC policy and procedures
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Type, quality and condition of LOTO tools and parts.......
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Removal of locks and tags after job is finished is controlled and monitored.
2.3 Labeling switches, isolator a and valves
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All isolator so/switches/circuits/cables and contact breakers labeled and well arranged
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Are there emergency stop button, red colored?
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Are all critical isolator so/valves identified (natural gas, main water supply, process emergency shut off, etc.)
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Are all critical isolator so/valves identified (natural gas, main water supply, process emergency shut off, etc.)
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Are all critical isolator so/valves identified (natural gas, main water supply, process emergency shut off, etc.)
2.4 Ladders, stairs, walkways (scaffolding)
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Condition of ladders, stairs, walkways, scaffold, etc.
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Ladders (portable/fixed) and scaffolds numbered, on registered
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Are ladders inspected periodically for deficiencies and does supervisors ensure corrective actions are taken.
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Stairways landing, open end platforms etc. toeboards.
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Storage on offices, etc., handrai, toeboards and access
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Stairways: four or more risers required handrail
2.5 Lifting gear and Records
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Condition of cranes/man baskets/hooks/chains/slings, etc.
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Listing gear identified and corrected in register
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Safe Work Load marked.
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Operator/driver trained and licensed
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Safety latches on all hooks where practicable.
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Storage and inspection of lifting tackle.
2.6 Compressed gas cylinders: Pressure vessels and records
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Pressure vessel on register, tests and inspection carried our (test pressure 1.3 x MSWP)
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Relief valves locked or sealed Red line on pressure gauge
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Are all gas cylinder stored properly? And used in a safe manner.
2.7 Hazardous Substances Control
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Alphabetical list of all substances
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Has a hazardous substance risk assessment and analysis been conducted based on an alphabetical list?
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Person designated to coordinate the list of MSD's
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MSDS sheets available in department, by buyer and first aid.
2.8 Risk Assessment (HIRA)
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Assessor a have attended risk assessment workshops
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Hazard identification done covering all possible hazards using proper analysis techniques(audit hazel, fmea, etc)
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Risk register for all workplace activities kept
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Risk assessment completed as per standard
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Probability, severity and frequency considered
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All expected risk in the work place are assessed especially in risk areas
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Quality of hazard identification and risk assessment reports. Effective analysis, evaluation and control measure
2.9 Motorized Equipment: Checklist, licensing
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Condition of vehicles/equipment/seat belts use
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Daily checklist completed by driver/ operator
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Driving cab, load area are clean and tidy
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Driver/operator training syllabus
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Employee attended and passed defensive driving course
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Internal licensing
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Validity of Government licensež
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Identification of drivers/operators
2.10 Portable Electrical Equipment
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Condition of all cords, plugs, switches, etc.
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All portable equipment identified, checked and register kept (all equipment fed through a flexible cable from plug point-110, 220, 380 or 500V)
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Are faulty items marked/tagged and removed from use?
2.11 Electrical Equipment
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List of all high risk electrical equipment and maintenance schedules
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Records of maintenance available
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Report to management on completed maintenanace
2.12 General Electrical Installation and Flameproof
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Electrical installation safe/earth leakage, GFCI
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Substations/panel/DB/faceplates locked or closed
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Is there any unsafe temporary wiring? or any damaged or faulty switches, plugs, joints, fuse boxes or distribution boards, etc.
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Flameproof equipment -annual checks and record of checks, e.g. Logbook
2.13 Hand Tools
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Condition of hand tools
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Regular checks by supervisor
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Storage of tools (includes hammers, chisels, files, brooms, mops, spades, wheelbarrows, handcarts, etc.
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Are damaged items marked/tagged and removed?
2.14 Ergonomics
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Survey carried out using a checklist covering all premises, furniture and jobs
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Develop checklists per standard
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Operators comfortable<br>-seating/computer and work stations<br>-accessibility-valves, switches, levers, etc.<br>-heat stress workload
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Ergonomics Commitee formed and top 10 hazards in current year identified
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Follow-up action/surveys as required
2.15 Head Protectors
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Risk assessment done/signs posted
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Provided and worn where necessary
2.16 Eye Protectors
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Risk assessment done/signs posted
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Eye protection provided and worn
2.17 Footwear
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Risk assessment done/signs posted
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Safety footwear provided
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Safe footwear being worn and in good condition
2.18 Protective Equipment
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Risk assessment done/signs posted
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Protective clothing provided and maintained
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Arc flash PPE/levels defined/worn
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All clothing worn: adequate, clean and in good repair
2.19 Respiratory Equipment
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Risk assessment done/signs posted
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Correct types provided, used checked and controlled
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Personnel trained in use of respiratory equipment
2.20 Hearing Conservations
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Noise survey conducted and areas zoned
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Reduction of noise at source
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Hearing acuity testing 6-monthly
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Approved hearing protectors provided and worn
2.21 Safety Harness
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Fall protection risk assessment done/sign posted
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Safety harness provided and used
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Conditions and regular checks
2.22 Hand Protection
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Risk assessment done/sign posted
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Gloves, barriers cream, etc. provided and worn/used
2.23 Control of Usage, issue maintenance and Record of personal protective equipment
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Commitment obtained from wearer accepting conditions and requirements to wear ppe/arc flash ppe
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Regularly checks by supervisor
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Are damaged items marked, listed and removed immediately from service?
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Record of equipment issued
2.24 Notices and Signs: Electrical, Mechanical,Protective Equipment, Symbolic Safety Signages
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Standardized signs posted where required- in good condition
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Display of signs of information and training
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Electrical warning notices/live conductors and substations
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Record of equipment issued
SECTION 3: Fire Protection and Prevention Protection
3.1 Fire Extinguishing Equipment
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Fire risks identified and assessed for all areas
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Action plans to correct deviations?
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Adequate number of correct types of fire extinguishing equipment provided and correctly located.
3.2 Locations Marked, Floor Clear
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Equipment location uniformly marked "keep clear"areas demarcated and maintained
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Equipment unobstructed
3.3 MaintenAnce of Equipment
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All fire extinguishing equipment numbered/identified on register and checked monthly
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Maintenance at least annually
3.4 Storage of flammable and Explosive Material
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Storage provided with suitable doors, windows (if any), ventilation, bund, etc.
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Store/magazine neat, tidy and clean/bonding
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List of flammables, precautions and storage capacity displayed?
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Spill control/secondary containment
3.5 Alarm System
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Independent alarm
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Back up alarm
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Is these test alarm
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Employees know the sound of alarm
3.6 Firefighting Drill and Instruction
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Fire teams adequate to risk as determined by fire risk assessment
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Team available on all shifts
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Fire drills-minimum once a year
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At least one evacuation drill per year (where not possible), at least publicized plan
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Someone in each department, other than fire team, trained in the use of fire extinguishers
3.7 Security Systems
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Control of entry and exit of persons, vehicles, etc.
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Security staff reporting unsafe practices/conditions
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One person per shift trained on 5 star Safety Workshop
3.8 Emergency Planning
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Emergency plans available, updated, signed
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Separate firs aid and services teams trained and included in emergency drills
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Coordinator to take control
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Employee training on site emergency plan
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Control Center/emergency equipment
3.9 Fire Prevention and Protection Coordinator
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Appointed in writing, duties defined
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Minimum training FPA one week course or similar
SECTION 4: Accident Recording and Investigation
4.1 Occupation Injury/Disease Record
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Official record/register/record of injuries as required by legislation or claimed GOSI (work men's group)
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Description of accident in register
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Reportable accidents being reported to authorities
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Minor injuries being recorded
4.2 Internal Accident/Near Miss Reporting and Investigation(Occupational Injury and/or disease)
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Internal report of all injuries/diseases/near miss incidents
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Investigation by designated investigator
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Causes identified/basic/immediate
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Effective recommendations
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Action taken/signed by manager
4.3 Injury/Disease/Near Miss Statistics
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Progressive statistical data: monthly and 12 months
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Graphic display of experience/graph/bar chart
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Analysis of injuries, part of body, department, etc.
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Statistics circulated to top managers and discussed at safety committee meetings
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Statistics displayed on notice boards
4.4 Internal Accident Reporting and Investigation (Damage, and other)
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Internal repor-damage and other
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Investigation:Designated investigator
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Cause identified/basic/immediate
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Effective recommendations
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Action taken/signed by manager
4.5 Accident (Damage) Statistics Kept
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Monthly and progressive 12 months
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Estimated and/or actual costs
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Statistics circulated to top managers
4.6 Cost of Risks:Apportioning of Costs
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Estimated costs of injuries and damage
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Graph circulated to managers monthly
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Other insurance claims compared to premiums
4.7 Near Miss Incident and Accident Recall
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Talks by foremen/supervisors used in conjunction with safety talks, meetings
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Review of previous events/accident
SECTION 5
5.1 Manager Designated as Responsible for safety and health
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Appointed in writing (whether full or part time)
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Designation of subordinate managers
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All managers and employees signed authority, responsibility and accountability for OSH commitment
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Endorsement of pertinent program documents (e.g. inspection reports, committee minutes and accident investigations) visible felt leadership
5.2 Person(s) Appointed for Safety and/or Occupational Hygiene Coordination.
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Pointed in writing (whether full or part time)
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Duties and responsibilities defined
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Safety training:5 Star System training workshops
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Safety system inspecting and auditing Course/Nebosh 1 week
5.3 Designation of Safety Representatives in Accordance with SEC Requirements
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Written appointment of Safety Representative (10%)
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Routine discussion of duties
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Monthly inspection of work areas using a checklists for reporting back
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Training:Safety Representative Course/Accident Investigation/other
5.4 Safety Committees
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Safety committees established as per standard
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Are all departments/divisions/sections represented
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Meeting once a month
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Minutes kept, detailing action to be taken and responsibility for the action
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Endorsed by Management and chairman of the safety committee
5.5 Other Communication Systems
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Toolbox talks related to possible hazards applicable to the task in hand
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Small group Activity System (productivity/quality Control Circles
5.6 First Aiders and Facilities
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Facilities to meet SEC requirements (full time nurse)
5.7 First Aid Training
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Five percent of complete staff to be trained or retrained to at least general level of first aid per year (Points allocated proportionally to % trained, e.g. 5% = 5, 4% = 4, etc.
5.8 Posters, Bulletins, Newsletters, Safety Films and Internal Competitions, etc.
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Posters displayed at specified display points rotated at least once weekly and explained
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Safety newsletter/bulletin-3 monthly
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Safety Videos/DVD screened-all to see
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Internal safety competition
5.9 Safety and Star Grading Board
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Up-to-date Safety Notice board policy/standard
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Star grading board and displAy of stars
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Board promoting Road Safety
5.10 Suggestion Scheme
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Formal/through safety committees
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Record of suggestions and acknowledgements
5.11 Safety Reference Library
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Safety Manual, Health and Safety system booklet, "black book", MSDS, 5 Star Standards
5.12 AnnUal Report-Safety Achievements
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Annual achievements publicized (report y AU manager on KPI's, etc
5.13 Induction and Job Safety Training
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Safety rules for all employees
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Induction includes safety instructions
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Job/task training includes the safety aspects of the job
5.14 Approved Safety Training Course
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5% of staff, including management, trained each year (points to be allocated proportionally to the percentage of staff trained)
5.15 Medical Examinations
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Pre-employment medical employees
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Man-job specification available to medico
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Regular medical school-e.g., scheduled substance food handlers, senior managers, equipment operators
5.16 Plant Inspection:Safety Reps
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Monthly inspection by Safety Reps or appointees submitting reports
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Checklist based on the 5-Star System being used
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Correction actions taken- follow-up and monitoring of uncorrected/ completed observations
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Reports considered and auctioned/signed by Management
5.17 Management Self-Audits
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Audit by team including management
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Each element of the 5 Star Safety System given consideration.
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At least 6 monthly self-audit
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Follow-up cation taken
5.18 Safety Specifications: Purchasing and Engineering Control New Plant and Contractors
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Safety specifications for purchasing new plant: machine guarding, color coding, LOTO requirements
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Re-commissioning/pre acceptance inspection, deviations corrected
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Pre-bid documents completed and filled by all contractors
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Contractors to comply with 5 Star safety rules, work area inspected, and deviations corrected
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Contractors reporting injuries and fatalities
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AU follow-up on deviations recorded and corrective action applied
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After submission, all contractor's evaluations kept including safety program
5.19 Written Safe Work Procedures
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Critical tasks identified and listed as per standard
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CT identification carried by trained persons
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Have all departments/divisions/sections with the AU been covered?
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Have all CT (Critical Task) even discussed with subject/job experts to get input before being finalized
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All CT .analysis documents kept for future revisions
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Safe Work Procedures written as per standard and available JSP's
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Do the SWP include tools, equipment and PPE/clothing needed to performed the tasks
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Adoption of AU managers/senior manager/business line VP
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Do the SWP include tools, equipment and PPE/clothing needed to performed the tasks
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SWP is used and shared
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SWP readily available
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Are the procedures written in a simple, easy to read and understandable format? Reviewed Annually
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Improvement suggestions, revision and workers feedback, is documented and reflected in SWP
5.20 Planned Job Observations
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All PJ observations have been planned
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Are all supervisors in possession of JSP's for their sections
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Planned Job Observations carried out as per scheduled
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Planned Job Observations carried out by trained supervisor or senior personnel
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All task safe work procedures have been covered
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Quality of schedule and observation reports
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History of corrections made to SWPs
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Actions taken to correct deviations/update job procedures
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Changes shared and updated SWP's used
5.21 Work Permits
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Areas/job identified where permits required
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Issuers identified
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Unified permit system used in all sites
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Permits used and displayed where required
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Isolation points clearly written on attached with WP
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Permits completed and fully filledk
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WP system quality
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Finished jobs and equipment release are covered by issuers, form signed and site checked
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Permits issued/received/signed off by responsible persons
5.22 Off The Job Safety
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Off the job propaganda used
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Off the job (road or other) accidents reported
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Propaganda, training and education directed at the identified causes
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Families and friends safety competitions
5.23 Safety Policy: Management Involvement
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Policy signed and publicized
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Managers taking ownership, active participation in safety activities and accountability
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Employees family with policy
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AU management involved, e.g. Attending evaluation/grading make resent actions, accident investigations, etc.