Etex EHS Audit - Compacted

Information

Audit Title
Client / Site
Conducted on
Prepared by
Location
Adit team
Site team

01.01 Policy & Objectives

· Implementation & Communication of Group H&S Policy & Rules (Up to Date BUGM signature on H&S Policy Posters, Policy Rules & Expectations referred to during induction and training programs)
Information
Good practice
· Is the policy well understood & actively promoted by the line management? Are H&S aspects driving the operational & business decisions?
Information
Good practice
· Site H&S Priorities & Objectives - check relevance of items, selection and decision making process, effectiveness of internal communication and delivery vs. target completion dates
Information
Good practice
· SMART H&S Objectives clearly defined for all Etex employees, H&S objectives should be aligned to the individual’s H&S responsibilities and they should be provided with the tools and training to achieve them.
Information
Good practice
· Does the plant managers promote a personnal safety vision with challenging objectives for the site?
Information
Good practice

02.01 Plant Management Engagement

· Does the Plant Manager engage employees in health and safety discussions (VFL) on a frequent & regular basis?
Information
Good practice
· Does the Plant Manager recognise and praise individuals who are performing their work in a safe manner?
Information
Good practice
· Are the managers on site driving the H&S processes and personnally involved in all H&S matters?
Information
Good practice
· Are the managers on site demonstrating real leadership in safety showing personal commitment?
Information
Good practice
· Are local initiatives and improvements communicated and shared with all members of the workforce?
Information
Good practice
· Are all health and safety incidents, regardless of severity fully investigated by site management and a relevant root cause identified?
Information
Good practice

02.02 Site Health & Safety Management System

· Site HSMS is aligned and achieves the objectives of the Group HSMS.
Information
Good practice
· A H&S Manual (Division, BU or Site) is readily available and includes all essential policy and rules relating to the H&S of the processes on site.
Information
Good practice
· Site H&S Management Organisation & Responsibilities have been defined for all Key functions outlining what is expected of them in terms of their contribution to the management of H&S at the site.
Information
Good practice

02.03 Site H&S Improvement Plan

· A Site H&S Improvement Plan is in place and reviewed and updated quarterly. It references A roadmap and the key Division / BU H&S Priorities and previous performance related issues.
Information
Good practice
· The Site’s H&S Priorities and KPIs have been reviewed and approved by the BUGM, Industrial Director & BU H&S Manager.
Information
Good practice
· Site H&S plan is part of a quarterly review process and the associated revenue and capital expenditure required is included in the Site & BU’s Budget Requirements.
Information
Good practice

02.04 Visible Felt Leadership (VFL)

02.04.01 Deployment

· Has the Site Management Team been trained to practice VFL interactions effectively?
Information
Good practice
· Does everyone at site understand the objective of the VFL process and been involved in an interaction either as interviewer or interviewee?
Information
Good practice
· Is there a tracking system in place and is the performance of the site management team against their personal targets monitored regularly?
Information
Good practice

02.04.02 Application

· Does the VFL process at site ensure that the findings are regularly reviewed and trends analysed?
Information
Good practice
· Are the VFL findings collected and treated on time to provide effective answer to the interviewees?
Information
Good practice

03.01 Employee Involvement

· Is there a process to actively seek the feedback & suggestions of employees?
Information
Good practice
· Are employees active in enhancing the health & safety of their working environment?
Information
Good practice
· Are employees freely engaging each other on safety issues (including unsafe behaviour)?
Information
Good practice
· Are employees actively participating to root causes analysis, risk assessments, near-miss & unsafe conditions reporting?
Information
Good practice

03.02.01 Safety Committee Involvement

· Have Safety Committee meetings been organised at least four times per year, held and chaired by the site manager?
Information
Good practice
· Have Safety Representatives (SR’s) been trained and do they understand and fulfil their role under the Etex policy?
Information
Good practice
· Do the SR’s contribute to the effective implementation of the Site HSMS and the Site Improvement Plan?
Information
Good practice
· Is there a strong sense of partnership between the management team and the employees/contractors and is this leveraged to support the site’s top priorities and performance improvement objectives?
Information
Good practice

03.02.02 – Feedback From a H&S Committee Member

· Is there a regular survey to collect employees’ opinions about the site HS culture?
Information
Good practice
· Are the outcomes addressed in the Site H&S Improvement Plan?
Information
Good practice
· Is the HS Committee involved in reviewing and monitoring the incident investigation process?
Information
Good practice
· Does the HS committee contribute to the local inspections and audits, promoting good practices and supporting efforts to deal with areas for improvement?
Information
Good practice

04.01 Risk Management

· Is there a system to ensure a preventive risk assessment of the place & tasks to be done in the plant? Are these risk assessments used to prioritise actions to reduce risk exposure in the entity?
Information
Good practice
· Is there a procedure to define a dynamic risk assessment before a (routine/ non-routine) task is performed? Are the employees performing such risk assessment (STOP/LMRA method)?
Information
Good practice
· Is there a procedure or process to manage the risks associated with any new equipment or activities prior to them being introduced into the workplace?
Information
Good practice
· Is there evidence that this has been deployed effectively?
Information
Good practice

04.02 Contractor Safety Management (CSM)

· Are Etex Managers/Supervisors aware of their responsibilities with respect to the health, safety and welfare of sub-contractors working in their areas of the plant?
Information
Good practice
· Does the site have an appointed contracts co-ordinator?
Information
Good practice
· Is there an induction process for contractors when they arrive on site which appraises them of the risks on site and what Etex expects of them?
Information
Good practice
· When meeting contractors on site question them on:-- Pre-qualification process- Level of competence / qualifications required- Method statements?
Information
Good practice
· Is there a process for evaluating the work of the contractor and providing feedback on their H&S performance?
Information
Good practice

04.03 Work at Height (WAH)

· Are WAH Risk Assessments documented and regularly upgraded?
Information
Good practice
· Are WAH Permits to Work completed by a competent person (when required) ?
Information
Good practice
· Is the WAH Deployment Program regularly confirming that the relevant provisions are being complied with and determining when any outstanding CAPEX requirement will be released?
Information
Good practice
· Is the review of WAH activities monitored by the internal audit process?
Information
Good practice
· Are the WAH equipment (scaffolds, ladders, MEWP…) properly managed (inspected regularly & in good conditions)
Information
Good practice

04.04 PPE

· PPE has been carefully selected with purchasing department and provided to anyone when required
Information
Good practice
· PPE standard from Etex has been followed and implemented timely
Information
Good practice
Information
Good practice
· Qualitative assessment is done for any PPE to ensure suitable provision
Information
Good practice
· Facilities are provided to maintain and to store PPE in permanent good condition
Information
Good practice
· PPE required are applied to employees as well as contractors
Information
Good practice
· Based on risk assessment, complementary specific PPE are provided (gloves, ear protection)
Information
Good practice

04.05 Mobile Equipment

· Was the Mobile Equipment Advisory (MEA) taken as reference to perform a specific site risk assessment?
Information
Good practice
· Is there an up to date site circulation plan in place?
Information
Good practice
· Is there effective segregation of vehicles and pedestrians on the site?
Information
Good practice
· Is there an effective system to ensure drivers skills are relevant and refreshed for any mobile equipment used on site?
Information
Good practice
· Do pedestrians wear High Visibility Clothing when working in operational areas whatever their status; employee, contractor, visitor, truck drivers?
Information
Good practice

04.06 Energy Isolation (EI) & LockOut TagOut TryOut (LOTOTO)

· Is there a site LOTOTO procedure in place and is it regularly reviewed and revised?
Information
Good practice
· Has everyone received basic training in the principles associated with effective LOTOTO practices?
Information
Good practice
· Is everyone provided with a personal lock?
Information
Good practice
· Is there a clear Site EI Deployment Strategy, to assess risks and determine the corrective actions required?
Information
Good practice
· Has the EI training been developed to target various audiences on time in an effective way?
Information
Good practice
· Have relevant EI procedures been developed by the site to control (Machine Equipment process) MEP EI risks?
Information
Good practice
· Has site revenue & CAPEX been defined referencing Group & Divisional standards based on risk control?
Information
Good practice

04.07 Conveyors - Machinery

· Has a risk assessment been performed to prevent any ‘black spot’ exposure?
Information
Good practice
· Are guarding and protectors in place and are they maintained in good condition?
Information
Good practice
· Is there an effective training program for every employee or contractor prior to them being asked to work on or near a conveyor?
Information
Good practice

04.08 Housekeeping

· Does the site maintain a high visual standard of housekeeping?
Information
Good practice
· Are there procedures in place to ensure the regular removal and disposal of waste streams for each workplace?
Information
Good practice

04.09 Lifting & Rigging

· Is there suitable equipment available to ensure equipment can be lifted safely?
Information
Good practice
· Is there a planned maintenance and inspection scheme for the lifting equipment and cranes to ensure that they are maintained in a safe condition?
Information
Good practice
· Have people been suitably trained to plan and assess the risks associated with the lifting of equipment in order that it can be completed in a safe manner?
Information
Good practice
· When using cranes are correct methods used to ensure that the load is moved safely without danger to the person below or other persons working in the area around the load (ref also lifting and rigging advisory)?
Information
Good practice

04.10 Use of hand tools

· Are the hand tools designed following code of practice and maintained in good condition?
Information
Good practice
· Are the tools used appropriately and stored in safe and clean conditions?
Information
Good practice

04.11 Occupational Health

04.11.01 Noise

· Have all the areas where noise is a hazard been identified? Is the relevant PPE provided where and when necessary?
Information
Good practice
· Have measurements of noise levels been taken by a competent person, using adequate and calibrated equipment, for each area where there is a likely risk?
Information
Good practice
· Has there been an effective programme to reduce noise levels so far as is reasonably practicable by means other than hearing protection?
Information
Good practice
· Have there been re-surveys organised where new machinery is installed, plant is significantly modified or operating conditions alter significantly?
Information
Good practice

04.11.02 Dust (Measurement & Control)

· Has a system of risk assessment been put in place to evaluate potential dust exposure? (dosimeter, nature of dust, density, potential health impact?)
Information
Good practice
· Is the Hierarchy of Control - HOC approach implemented to control risk exposures?
Information
Good practice
· Is there annual control to make sure the site is complying with legal and Etex requirements (WAMP) ?
Information
Good practice

04.11.03 Hazardous Substances

· Is there an inventory of all the potentially hazardous substances used on the site?
Information
Good practice
· Are the relevant data sheets available for the hazardous substances contained within the site inventory?
Information
Good practice
· Has a risk assessment been completed which identifies the potential level of exposure and the control measurements that need to be adopted?
Information
Good practice
· Are the people who need to use the hazardous substances aware of and trained for the risks they present and the control measures they need to adopt?
Information
Good practice
· Is any associated engineering control or personal protection equipment maintained in a suitable condition?
Information
Good practice

04.11.04 Manual Handling (Ergonomics)

· Does the local policy recognise the hazards posed by manual handling, musculoskeletal disorders, and from use of vibratory tools?
Information
Good practice
· Are responsibilities defined to ensure that new risks are identified and have all areas where manual handling is a hazard been identified?
Information
Good practice
· Is there a system of assessment applied to manual handling hazards which takes into account the load, the task, the individual, and the work environment?
Information
Good practice
· Are the standards defined in accordance with ergonomic rules, regulations, or code of practice?
Information
Good practice
· Is there a planned approach to progressive reduction in risks from manual handling and have control measures been implemented which have reduced risk, including safe systems of work?
Information
Good practice
· Is there evidence that supervision is applied to ensure that specific systems of work and good manual handling techniques are being followed?
Information
Good practice

04.11.05 Health, others

- Heat exposure
Information
Good practice
- Lighting
Information
Good practice
- ACM inventory / plan / instructions for work
Information
Good practice
- Alcohol& Drugs
Information
Good practice

04.12 Stock Pile Management

· Are procedures defined and communicated that limit and strictly control access to surge piles and stockpiles?
Information
Good practice
· Are procedures defined and communicated that prevent access to surge piles?
Information
Good practice
· Is signage posted that controls or prevents access to surge piles and stockpiles?
Information
Good practice

04.13 Geotechnical Management

· Is there a geotechnical design document available, which defines the working method for the quarry faces? (this should account for:- direction / face heights / geological anomalies)
Information
Good practice
· Is there a process in place that monitors that the geotechnical design is being followed?
Information
Good practice
· Is there an inspection regime that monitors face conditions and ensures that they are maintained in a safe condition?
Information
Good practice
· Are other structures, e.g. stockpiles and lagoons, designed referencing engineering principles in order to avoid failure?
Information
Good practice
· Have people been trained in the working method and made aware of the risks associated with quarry working?
Information
Good practice

04.14 Electrical Installation

· Do employees and contractors appreciate the dangers associated with working on Electrical Equipment?
Information
Good practice
· Is there a documented plan of the site’s electrical sources, overhead or buried power lines and wiring schemes for plant and equipment?
Information
Good practice
· Is the documentation routinely updated following changes?
Information
Good practice
· Is there evidence of a formal assessment of the electrical risks associated with elements of the distribution network, plant, machinery and related control systems?
Information
Good practice
· When installing new equipment is the amount of power required compared to the capacity of the distribution network?
Information
Good practice
· Is there a clear understanding of the over-riding legal requirement not to work on electrically live circuits and is there a clear definition of live work with formal authorised Permit to Work - PTW control processes?
Information
Good practice
· Is there a formal system of maintenance work which ensures the isolation of power, and testing, to prove ‘dead’, which prevents inadvertent restoration?
Information
Good practice
· Are parts of the distribution system or electrical cabinets in exposed positions protected by physical barriers and are electrical panels kept clear, locked, clearly labelled, and is there an issue control list for panel keys?
Information
Good practice

04.15 Mechanical Structures

· Is someone named as responsible to ensure the safety of buildings and structures on site?
Information
Good practice
· Has the condition of site buildings and structures been assessed for structural integrity at appropriate intervals and does the appearance of buildings suggest that they are maintained in good order?
Information
Good practice

04.16 Welfare Provision

· Are canteen facilities and rest areas maintained and inspected regularly to ensure satisfactory standards of hygiene?
Information
Good practice
· Are there rules for the prevention of inappropriate eating / drinking in the workplace?
Information
Good practice
· Are suitably maintained washing and toilet facilities available to all workgroups? Is a good standard of hygiene demonstrated?
Information
Good practice
· Are employees provided with dry and secure accommodation for clothing and personal affairs whilst they are at work?
Information
Good practice

· Is clean drinking water provided, and has it been labelled as such?
Information
Good practice

04.17 Confined Spaces

· Have all the confined spaces on the site been identified and suitable signage posted?
Information
Good practice
· Has a risk assessment been prepared for every confined space entry?
Information
Good practice
· Is there a site corrective action plan designed to address any deficencies identified by the confined space risk assessment?
Information
Good practice
· Is there evidence of permits to work being issued prior to a confined space entry?
Information
Good practice
· Have people been trained in their responsibilities during a confined space entry and are they aware of the risks and the method of control?
Information
Good practice
· Is suitable equipment readily available to enable the control measures specified by the related Risk Assessment to be deployed effectively?
Information
Good practice

04.18 Logistsics transport

Contractors / companies: - have contractors been selected on HS performance as well, - is the contract including HS, - do the same rules apply for subcontractors (and are they agreed with ETEX, - is the use of spot-hauliers avoided
Information
Good practice
Drivers: - Do drivers have a license, are they medically checked - Are they separately trained for the ETEX requirements - Respect rules of the road, do not take A&D, respect driving hours - Use required PPE on site of ETEX
Information
Good practice
Vehicles: - Have standard safety equipment and all all other standard equipmet fitted - Do not enter the site in unsafe condition (breaks, tires, steering wheel..) - have been maintained , serviced and inspected acc to builders manual - have done a prestart check before leaving - Lights on all day and night
Information
Good practice
Journey management : - preferred roads are used with safe rest areas - inventory of actual bottle necks and black spots before leaving - No passengers for which no safe seat are present are permitted
Information
Good practice
Loading/unloading: - Clear instructions when arriving at site(s) - Truck is loaded safely, respecting max load/distribution - Unloading is done safely, esp. preventing tip-over of trucks - During (un)loading truck drivers are in a safe area
Information
Good practice

04.19 People transport

Contractors / companies: - have contractors been selected on HS performance as well, - is the contract including HS, - do the same rules apply for subcontractors (and are they agreed with ETEX), - is the use of spot-hauliers avoided
Information
Good practice
Drivers: - Do drivers have a license, are they medically checked - Are they separately trained for the ETEX requirements - Respect rules of the road, do not take A&D, respect driving hours - Use required PPE on site of ETEX
Information
Good practice
Vehicles: - Have standard safety equipment and all other standard equipmet fitted - have been maintained , serviced and inspected acc. to builders manual - have done a prestart check before leaving - Lights on all day and night
Information
Good practice
Journey management : - preferred roads are used with safe rest areas - inventory of actual bottle necks and black spots before leaving - No passengers for which no safe seat are present are permitted
Information
Good practice
Loading/unloading: - One seat, One passenger, One safety belt - Luggage physically seperated from passengers
Information
Good practice

04.20 storage / racks

- storage racks are in good state, max load is indicated and safety instructions are posted.
Information
Good practice
- racks are inspected frequently internal (visually) and external.
Information
Good practice

05.01 Emergency/Crisis Management

· Is the Emergency Policy held on site and is the system operating fully on the site?
Information
Good practice
· Is the Crisis Management organisation formally in place to deal with critical HS issues (e.g. death, explosion, fire or flood)?
Information
Good practice
· Is there specific training provided for people with critical roles in the Crisis Management Organisation?
Information
Good practice
· Is there a regular practical test or simulation to review effectiveness of the crisis management, including communication ?
Information
Good practice

05.02 Fire Safety

· Are employees aware of precautions and procedures in their workplace?
Information
Good practice
· Are fire alarm call points tested weekly, including audibility and are there evacuation drills in all buildings twice yearly including all shifts?
Information
Good practice
· Are fire protection devices (extinguishers, sprinklers) controlled and maintained in good condition?
Information
Good practice

06.01 Incident Management

· Any Injury or Significant Near Miss Incident is systematically investigated and reviewed.
Information
Good practice
· Serious Event Review’s (SER) and Good Practices circulated by the Group/Division are reviewed by the site management team and any relevant key learning’s are implemented effectively.
Information
Good practice
· Injuries, First Aid, Near Misses are reported in accordance with the Group R & Inv Standard and trends are analysed for key learning’s and actions.
Information
Good practice

07.01 HR Processes

07.01.01 Organization and Human Resource (OHR) Review

· H&S is fully integrated into the OHR review process. An individual’s H&S Performance is taken into account and has an influence on their career path
Information
Good practice

07.01.02 Recruitment

· Job definition profiles – are they defined with HS issues being considered as part of the recruitment process? (skills requirement, physical capabilities, HS leadership issues, etc.)
Information
Good practice
· Is a Health Questionnaire completed during the recruitment process in order to assess the individual’s state of health and their capacity to perform the role they are being recruited for?
Information
Good practice
· Prior to any recruitment (or before confirming final process) is there a systematic initial medical check to assess candidate profile versus job requirements?
Information
Good practice
· As part of the personal background check is the previous HS experience of the recruit recorded and presented to the N+1 of the new employee?
Information
Good practice

07.01.03 Induction

· Is there a documented induction process established for any person visiting the site, regardless of status? (employee, contractor, visitor)
Information
Good practice
· Does the induction program include HS Policy & Rules applicable at site and what to do in the event of an incident?
Information
Good practice
· Does the Induction program include practical training related to the HS specific risks of the new persons workplace?
Information
Good practice

07.01.04 Ongoing Development & Competence

· Is there a site annual training plan established and controlled to make sure all legal requirements are covered?
Information
Good practice
· Is there an individual training needs analysis and an associated personal training plan developed and deployed for all permanent employees to match their HS responsibilities attached to the job position?
Information
Good practice
· Is there tracking system ensuring the quality and delivery of training is done to provide relevant personal development and HS competence?
Information
Good practice
· Are employees trained to recognise accidents and do they understand the part they have to play in the reporting of accidents?
Information
Good practice

08.01 Communication

· The site has established a dialogue with local community, industry-related associations, governments and NGOs about H&S via a Stakeholder Relations program.
Information
Good practice
· The BU and sites use signage, posters and H&S Etex documents that are consistent across the Etex activities. Posters are selected by local management to support campaigns and sustain H&S motivation. Local staff is contributing to this process
Information
Good practice
· The safety results are presented in a dynamic and attractive way, published and posted regularly and everyone working on site is able to understand the meaning and the trend. This information contributes to encourage H&S involvement
Information
Good practice
· Learning’s from audits / inspections and from internal / external incidents or injuries investigated are posted on noticeboards and discussed on site during regular meetings.
Information
Good practice
· Regular Exposure to SER or Fatality lessons through toolbox talks or briefings are organized on site, using Etex group publications or benchmarking data.
Information
Good practice
· Success stories are widely communicated: special follow up of publications and implementation is included in the H&S Management system of the BU / Site to make sure new ideas are captured and used timely and appropriately. · Accomplishments and milestones are recognized and celebrated through special Awards ceremonies, at the site / BU level and represent a real motivational process for employees
Information
Good practice
· Communication is designed to enhance employee motivation and awareness and increase consistent use of safe practices in their daily work activities
Information
Good practice
Information
Good practice

09.01 Documentation and Record Keeping

· Systems are designed and implemented for creating, distributing, controlling and managing documents and records prepared in support of Health and Safety requirements.
Information
Good practice
· Records are defined as written documentation of activities that have taken place such as training records, meeting minutes, etc.
Information
Good practice
· The documents and records management systems comply with regulatory requirements on data protection, medical confidentiality and document retention. etc.
Information
Good practice

10.01 Management Review

· Does the Plant Manager regularly review the site Health and Safety Improvement Plan and confirm that corrective actions are closed out in a timely manner?
Information
Good practice
· Are the findings of RCA or internal and external audits & inspection, worker suggestions implemented and reviewed by the management and prioritization set up accordingly?
Information
Good practice
· The site is regularly audited and inspected; a BU Audit Programme should be available for review to check frequency and completion rates.
Information
Good practice

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01.01 Policy & Objectives

02.01 Plant Management Engagement

02.02 Site Health & Safety Management System

02.03 Site H&S Improvement Plan

02.04 Visible Felt Leadership (VFL)

02.04.01 Deployment

02.04.02 Application

03.01 Employee Involvement

03.02.01 Safety Committee Involvement

03.02.02 – Feedback From a H&S Committee Member

04.01 Risk Management

04.02 Contractor Safety Management (CSM)

04.03 Work at Height (WAH)

04.04 PPE

04.05 Mobile Equipment

04.06 Energy Isolation (EI) & LockOut TagOut TryOut (LOTOTO)

04.07 Conveyors - Machinery

04.08 Housekeeping

04.09 Lifting & Rigging

04.10 Use of hand tools

04.11 Occupational Health

04.11.01 Noise

04.11.02 Dust (Measurement & Control)

04.11.03 Hazardous Substances

04.11.04 Manual Handling (Ergonomics)

04.11.05 Health, others

04.12 Stock Pile Management

04.13 Geotechnical Management

04.14 Electrical Installation

04.15 Mechanical Structures

04.16 Welfare Provision

04.17 Confined Spaces

04.18 Logistsics transport

04.19 People transport

04.20 storage / racks

05.01 Emergency/Crisis Management

05.02 Fire Safety

06.01 Incident Management

07.01 HR Processes

07.01.01 Organization and Human Resource (OHR) Review

07.01.02 Recruitment

07.01.03 Induction

07.01.04 Ongoing Development & Competence

08.01 Communication

09.01 Documentation and Record Keeping

10.01 Management Review

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