Information

  • Audit Title

  • Document No.

  • Client / Site

  • Conducted on

  • Prepared by

  • Location
  • Personnel

SECTION 1: Premises and Housekeeping

1.1 Building and Floors

  • Obvious unrepaired damage buildings

  • Unsafe condition of floors, carpets, roadways, walkways, elevated platforms

  • Have these deviations have been reported.

  • Corrective action taken in timely manner

  • Premises divided into ares and delegated to Safety Representative/Supervisor/HSE (on plan or in writing)

1.2 Good lighting: Natural and Artificial

  • Sample lights out

  • Poorly lit areas

  • Reporting of lights out by safety reps/supervision/HSE monthly

  • Lighting survey and monitoring of light intensities

  • Have been survey results and recommendations been auctioned/planned

  • Safety glass or similar used in hazardous areas

1.3 Ventilation: Natural and Artificial

  • Study done for ventilation problems

  • Have study results and recommendations been applied.

  • Confined space area are identified, study done.

  • Ventilation extraction provided and maintained

  • Environmental monitoring/heat stress/sampling

1.4 Plant Hygiene Facilities

  • Facilities in a clean hygienic stage

  • No food in unauthorized areas

  • Regular monthly inspections

  • Checklist used signed, monitored

  • Is the problem being dealt wit

1.5 Pollution: Air, Ground, and Water

  • Study to determine whether a pollution problem exists

  • Have study results and recommendation been auctioned/applied

  • Hazardous waste identified

  • Obvious pollution/ uncontrolled fuel, oil leakage or hazardous waste

  • Is the problem being dealt with

1.6 Aisles and Storage Demarcated

  • Floors demarcated as per standard

  • Uninformed demarcation code used

  • Demarcation adhered to

  • Demarcation under electrical/mechanical equipment

1.7 Good Stacking and Storage Practices

  • Storage in cupboards, on shelves neat and tidy

  • No stacking on top of windowsills, cabinets, etc.

  • Unsafe conditions related to stacking an storage is reported and action taken

  • Stacking neat, stable and controlled

  • Storage in cupboards, on shelves neat and tidy

1.8 Housekeeping

  • Safety rep/appointees/HSE controlling areas by reporting (good general good housekeeping)

  • Under roof areas free of junk and materials

  • Corrective actions

1.9 Scrap and Refuse Bins Removal System

  • Scrap bins provided

  • Regular controlled removal

  • Separate bins for rags, oily materials, scrap, etc.

  • Bin locations demarcated

1.10 Color coding: Plant and pipelines

  • Uniform color coding

  • Color keyboard (legend) displayed

  • Knowledge of colors (own code acceptable)

SECTION 2: Mechanical, Electrical and Personnel Safeguarding

2.1 Machine/Hazardous Equipment guarding

  • All hazardous moving machine/ electrical parts within normal reach completely guarded/fenced/enclosed

  • All guards installed are listed,, checked and maintained

  • Inspection guards/front/back/back panels

  • Record of equipment issued

2.2 Lock-System and Usage "LOTO"

  • Written procedure available, updated and applied

  • One key, one lock, and one authorized person is applied whenever LOTO is required

  • Are tags and locks being used correctly

  • Are there task specific procedures available?

  • Are all affected staff trained?

  • Locks numbered and all use locks are recorded on permit

  • All equipment can be isolated and locked (including where fuses are drawn or valves in chemicals lines, etc.

  • LOTO are monitored, supervised and controlled by competent person and authorized person/LOTO station available and well arranged.

  • Do field activities match SEC policy and procedures

  • Type, quality and condition of LOTO tools and parts.......

  • Removal of locks and tags after job is finished is controlled and monitored.

2.3 Labeling switches, isolator a and valves

  • All isolator so/switches/circuits/cables and contact breakers labeled and well arranged

  • Are there emergency stop button, red colored?

  • Are all critical isolator so/valves identified (natural gas, main water supply, process emergency shut off, etc.)

  • Are all critical isolator so/valves identified (natural gas, main water supply, process emergency shut off, etc.)

  • Are all critical isolator so/valves identified (natural gas, main water supply, process emergency shut off, etc.)

2.4 Ladders, stairs, walkways (scaffolding)

  • Condition of ladders, stairs, walkways, scaffold, etc.

  • Ladders (portable/fixed) and scaffolds numbered, on registered

  • Are ladders inspected periodically for deficiencies and does supervisors ensure corrective actions are taken.

  • Stairways landing, open end platforms etc. toeboards.

  • Storage on offices, etc., handrai, toeboards and access

  • Stairways: four or more risers required handrail

2.5 Lifting gear and Records

  • Condition of cranes/man baskets/hooks/chains/slings, etc.

  • Listing gear identified and corrected in register

  • Safe Work Load marked.

  • Operator/driver trained and licensed

  • Safety latches on all hooks where practicable.

  • Storage and inspection of lifting tackle.

2.6 Compressed gas cylinders: Pressure vessels and records

  • Pressure vessel on register, tests and inspection carried our (test pressure 1.3 x MSWP)

  • Relief valves locked or sealed Red line on pressure gauge

  • Are all gas cylinder stored properly? And used in a safe manner.

2.7 Hazardous Substances Control

  • Alphabetical list of all substances

  • Has a hazardous substance risk assessment and analysis been conducted based on an alphabetical list?

  • Person designated to coordinate the list of MSD's

  • MSDS sheets available in department, by buyer and first aid.

2.8 Risk Assessment (HIRA)

  • Assessor a have attended risk assessment workshops

  • Hazard identification done covering all possible hazards using proper analysis techniques(audit hazel, fmea, etc)

  • Risk register for all workplace activities kept

  • Risk assessment completed as per standard

  • Probability, severity and frequency considered

  • All expected risk in the work place are assessed especially in risk areas

  • Quality of hazard identification and risk assessment reports. Effective analysis, evaluation and control measure

2.9 Motorized Equipment: Checklist, licensing

  • Condition of vehicles/equipment/seat belts use

  • Daily checklist completed by driver/ operator

  • Driving cab, load area are clean and tidy

  • Driver/operator training syllabus

  • Employee attended and passed defensive driving course

  • Internal licensing

  • Validity of Government licensež

  • Identification of drivers/operators

2.10 Portable Electrical Equipment

  • Condition of all cords, plugs, switches, etc.

  • All portable equipment identified, checked and register kept (all equipment fed through a flexible cable from plug point-110, 220, 380 or 500V)

  • Are faulty items marked/tagged and removed from use?

2.11 Electrical Equipment

  • List of all high risk electrical equipment and maintenance schedules

  • Records of maintenance available

  • Report to management on completed maintenanace

2.12 General Electrical Installation and Flameproof

  • Electrical installation safe/earth leakage, GFCI

  • Substations/panel/DB/faceplates locked or closed

  • Is there any unsafe temporary wiring? or any damaged or faulty switches, plugs, joints, fuse boxes or distribution boards, etc.

  • Flameproof equipment -annual checks and record of checks, e.g. Logbook

2.13 Hand Tools

  • Condition of hand tools

  • Regular checks by supervisor

  • Storage of tools (includes hammers, chisels, files, brooms, mops, spades, wheelbarrows, handcarts, etc.

  • Are damaged items marked/tagged and removed?

2.14 Ergonomics

  • Survey carried out using a checklist covering all premises, furniture and jobs

  • Develop checklists per standard

  • Operators comfortable<br>-seating/computer and work stations<br>-accessibility-valves, switches, levers, etc.<br>-heat stress workload

  • Ergonomics Commitee formed and top 10 hazards in current year identified

  • Follow-up action/surveys as required

2.15 Head Protectors

  • Risk assessment done/signs posted

  • Provided and worn where necessary

2.16 Eye Protectors

  • Risk assessment done/signs posted

  • Eye protection provided and worn

2.17 Footwear

  • Risk assessment done/signs posted

  • Safety footwear provided

  • Safe footwear being worn and in good condition

2.18 Protective Equipment

  • Risk assessment done/signs posted

  • Protective clothing provided and maintained

  • Arc flash PPE/levels defined/worn

  • All clothing worn: adequate, clean and in good repair

2.19 Respiratory Equipment

  • Risk assessment done/signs posted

  • Correct types provided, used checked and controlled

  • Personnel trained in use of respiratory equipment

2.20 Hearing Conservations

  • Noise survey conducted and areas zoned

  • Reduction of noise at source

  • Hearing acuity testing 6-monthly

  • Approved hearing protectors provided and worn

2.21 Safety Harness

  • Fall protection risk assessment done/sign posted

  • Safety harness provided and used

  • Conditions and regular checks

2.22 Hand Protection

  • Risk assessment done/sign posted

  • Gloves, barriers cream, etc. provided and worn/used

2.23 Control of Usage, issue maintenance and Record of personal protective equipment

  • Commitment obtained from wearer accepting conditions and requirements to wear ppe/arc flash ppe

  • Regularly checks by supervisor

  • Are damaged items marked, listed and removed immediately from service?

  • Record of equipment issued

2.24 Notices and Signs: Electrical, Mechanical,Protective Equipment, Symbolic Safety Signages

  • Standardized signs posted where required- in good condition

  • Display of signs of information and training

  • Electrical warning notices/live conductors and substations

  • Record of equipment issued

SECTION 3: Fire Protection and Prevention Protection

3.1 Fire Extinguishing Equipment

  • Fire risks identified and assessed for all areas

  • Action plans to correct deviations?

  • Adequate number of correct types of fire extinguishing equipment provided and correctly located.

3.2 Locations Marked, Floor Clear

  • Equipment location uniformly marked "keep clear"areas demarcated and maintained

  • Equipment unobstructed

3.3 MaintenAnce of Equipment

  • All fire extinguishing equipment numbered/identified on register and checked monthly

  • Maintenance at least annually

3.4 Storage of flammable and Explosive Material

  • Storage provided with suitable doors, windows (if any), ventilation, bund, etc.

  • Store/magazine neat, tidy and clean/bonding

  • List of flammables, precautions and storage capacity displayed?

  • Spill control/secondary containment

3.5 Alarm System

  • Independent alarm

  • Back up alarm

  • Is these test alarm

  • Employees know the sound of alarm

3.6 Firefighting Drill and Instruction

  • Fire teams adequate to risk as determined by fire risk assessment

  • Team available on all shifts

  • Fire drills-minimum once a year

  • At least one evacuation drill per year (where not possible), at least publicized plan

  • Someone in each department, other than fire team, trained in the use of fire extinguishers

3.7 Security Systems

  • Control of entry and exit of persons, vehicles, etc.

  • Security staff reporting unsafe practices/conditions

  • One person per shift trained on 5 star Safety Workshop

3.8 Emergency Planning

  • Emergency plans available, updated, signed

  • Separate firs aid and services teams trained and included in emergency drills

  • Coordinator to take control

  • Employee training on site emergency plan

  • Control Center/emergency equipment

3.9 Fire Prevention and Protection Coordinator

  • Appointed in writing, duties defined

  • Minimum training FPA one week course or similar

SECTION 4: Accident Recording and Investigation

4.1 Occupation Injury/Disease Record

  • Official record/register/record of injuries as required by legislation or claimed GOSI (work men's group)

  • Description of accident in register

  • Reportable accidents being reported to authorities

  • Minor injuries being recorded

4.2 Internal Accident/Near Miss Reporting and Investigation(Occupational Injury and/or disease)

  • Internal report of all injuries/diseases/near miss incidents

  • Investigation by designated investigator

  • Causes identified/basic/immediate

  • Effective recommendations

  • Action taken/signed by manager

4.3 Injury/Disease/Near Miss Statistics

  • Progressive statistical data: monthly and 12 months

  • Graphic display of experience/graph/bar chart

  • Analysis of injuries, part of body, department, etc.

  • Statistics circulated to top managers and discussed at safety committee meetings

  • Statistics displayed on notice boards

4.4 Internal Accident Reporting and Investigation (Damage, and other)

  • Internal repor-damage and other

  • Investigation:Designated investigator

  • Cause identified/basic/immediate

  • Effective recommendations

  • Action taken/signed by manager

4.5 Accident (Damage) Statistics Kept

  • Monthly and progressive 12 months

  • Estimated and/or actual costs

  • Statistics circulated to top managers

4.6 Cost of Risks:Apportioning of Costs

  • Estimated costs of injuries and damage

  • Graph circulated to managers monthly

  • Other insurance claims compared to premiums

4.7 Near Miss Incident and Accident Recall

  • Talks by foremen/supervisors used in conjunction with safety talks, meetings

  • Review of previous events/accident

SECTION 5

5.1 Manager Designated as Responsible for safety and health

  • Appointed in writing (whether full or part time)

  • Designation of subordinate managers

  • All managers and employees signed authority, responsibility and accountability for OSH commitment

  • 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.

  • Pointed in writing (whether full or part time)

  • Duties and responsibilities defined

  • Safety training:5 Star System training workshops

  • Safety system inspecting and auditing Course/Nebosh 1 week

5.3 Designation of Safety Representatives in Accordance with SEC Requirements

  • Written appointment of Safety Representative (10%)

  • Routine discussion of duties

  • Monthly inspection of work areas using a checklists for reporting back

  • Training:Safety Representative Course/Accident Investigation/other

5.4 Safety Committees

  • Safety committees established as per standard

  • Are all departments/divisions/sections represented

  • Meeting once a month

  • Minutes kept, detailing action to be taken and responsibility for the action

  • Endorsed by Management and chairman of the safety committee

5.5 Other Communication Systems

  • Toolbox talks related to possible hazards applicable to the task in hand

  • Small group Activity System (productivity/quality Control Circles

5.6 First Aiders and Facilities

  • Facilities to meet SEC requirements (full time nurse)

5.7 First Aid Training

  • 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.

  • Posters displayed at specified display points rotated at least once weekly and explained

  • Safety newsletter/bulletin-3 monthly

  • Safety Videos/DVD screened-all to see

  • Internal safety competition

5.9 Safety and Star Grading Board

  • Up-to-date Safety Notice board policy/standard

  • Star grading board and displAy of stars

  • Board promoting Road Safety

5.10 Suggestion Scheme

  • Formal/through safety committees

  • Record of suggestions and acknowledgements

5.11 Safety Reference Library

  • Safety Manual, Health and Safety system booklet, "black book", MSDS, 5 Star Standards

5.12 AnnUal Report-Safety Achievements

  • Annual achievements publicized (report y AU manager on KPI's, etc

5.13 Induction and Job Safety Training

  • Safety rules for all employees

  • Induction includes safety instructions

  • Job/task training includes the safety aspects of the job

5.14 Approved Safety Training Course

  • 5% of staff, including management, trained each year (points to be allocated proportionally to the percentage of staff trained)

5.15 Medical Examinations

  • Pre-employment medical employees

  • Man-job specification available to medico

  • Regular medical school-e.g., scheduled substance food handlers, senior managers, equipment operators

5.16 Plant Inspection:Safety Reps

  • Monthly inspection by Safety Reps or appointees submitting reports

  • Checklist based on the 5-Star System being used

  • Correction actions taken- follow-up and monitoring of uncorrected/ completed observations

  • Reports considered and auctioned/signed by Management

5.17 Management Self-Audits

  • Audit by team including management

  • Each element of the 5 Star Safety System given consideration.

  • At least 6 monthly self-audit

  • Follow-up cation taken

5.18 Safety Specifications: Purchasing and Engineering Control New Plant and Contractors

  • Safety specifications for purchasing new plant: machine guarding, color coding, LOTO requirements

  • Re-commissioning/pre acceptance inspection, deviations corrected

  • Pre-bid documents completed and filled by all contractors

  • Contractors to comply with 5 Star safety rules, work area inspected, and deviations corrected

  • Contractors reporting injuries and fatalities

  • AU follow-up on deviations recorded and corrective action applied

  • After submission, all contractor's evaluations kept including safety program

5.19 Written Safe Work Procedures

  • Critical tasks identified and listed as per standard

  • CT identification carried by trained persons

  • Have all departments/divisions/sections with the AU been covered?

  • Have all CT (Critical Task) even discussed with subject/job experts to get input before being finalized

  • All CT .analysis documents kept for future revisions

  • Safe Work Procedures written as per standard and available JSP's

  • Do the SWP include tools, equipment and PPE/clothing needed to performed the tasks

  • Adoption of AU managers/senior manager/business line VP

  • Do the SWP include tools, equipment and PPE/clothing needed to performed the tasks

  • SWP is used and shared

  • SWP readily available

  • Are the procedures written in a simple, easy to read and understandable format? Reviewed Annually

  • Improvement suggestions, revision and workers feedback, is documented and reflected in SWP

5.20 Planned Job Observations

  • All PJ observations have been planned

  • Are all supervisors in possession of JSP's for their sections

  • Planned Job Observations carried out as per scheduled

  • Planned Job Observations carried out by trained supervisor or senior personnel

  • All task safe work procedures have been covered

  • Quality of schedule and observation reports

  • History of corrections made to SWPs

  • Actions taken to correct deviations/update job procedures

  • Changes shared and updated SWP's used

5.21 Work Permits

  • Areas/job identified where permits required

  • Issuers identified

  • Unified permit system used in all sites

  • Permits used and displayed where required

  • Isolation points clearly written on attached with WP

  • Permits completed and fully filledk

  • WP system quality

  • Finished jobs and equipment release are covered by issuers, form signed and site checked

  • Permits issued/received/signed off by responsible persons

5.22 Off The Job Safety

  • Off the job propaganda used

  • Off the job (road or other) accidents reported

  • Propaganda, training and education directed at the identified causes

  • Families and friends safety competitions

5.23 Safety Policy: Management Involvement

  • Policy signed and publicized

  • Managers taking ownership, active participation in safety activities and accountability

  • Employees family with policy

  • AU management involved, e.g. Attending evaluation/grading make resent actions, accident investigations, etc.

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