Information
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Audit Title
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Document No.
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Prepared by
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Client / Site
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Conducted on
Red Tag Area
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Is there an established Red Tag area?
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All items have been dispositioned within 1 month
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Items are organized and accessible
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The area is clean (no oil spills, dirt, broken pallets, etc.)
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The Red Tag SOP is displayed in the area and tags are available for use
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Red Tag SOP is being followed, all items have a completely filled out red tag attached to them
Cleaning (oil leaks, electrical cabinets, resin spills, purgings, floors, cleaning stations)
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Dirt/Grime/Rust/Calcium/Salt build up has been removed from the equipment
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Corrected on
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Dock areas are clear and free of debris
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Corrected on
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Equipment is free of oil leaks
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Corrected on
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Exits/Interior exit routes/Exterior exit routes are clear of debris
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Corrected on
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Floors are clean, dry and organized (floor dry is only used as a temporary solution)
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Corrected on
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Half used tape rolls/fittings/twine are reasonably picked up and disposed
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Corrected on
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Overhead doors are free of debris
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Corrected on
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Purgings are picked up in an appropriate time frame and stored properly
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Corrected on
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Resin spills are swept up/contained(no open drains), Striper hose is not leaking
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Corrected on
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Scrap wood/Conduit/Misc. items have been removed from corners/window ledges/tops of cabinets
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Corrected on
Documentation (Training/Audits/Certifications/Team members)
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6S team members have been identified
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Corrected on
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Annual training is completed for all employees
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Corrected on
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CO monitoring and Crane/Hoist/Winch - Certification
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Corrected on
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LOTO training is current
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Corrected on
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Monthly 6S audits are being conducted and saved
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Corrected on
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Safety/5S training is completed for new employees
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Corrected on
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Tool box talks/Safety meeting documentation is saved
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Corrected on
Electrical
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All electrical cords/leads/outlets are in good condition
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Corrected on
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All strain reliefs/electrical connections are adequately installed/tightened
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Corrected on
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Ceramic covers are being used on heater bands
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Corrected on
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Conduit is straight and not damaged
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Corrected on
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Cord drops are installed where needed
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Corrected on
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Electrical boxes/transformers are securely fastened
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Corrected on
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Electrical cabinets are clear/free of debris/have safe clearance around them
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Corrected on
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Electrical doors are closed and all breakers are labeled
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Corrected on
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Emergency lighting/exit signs/dock lights are in working order and adequately placed
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Corrected on
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Exposed wire nuts/bare wires/heater studs/missing knockouts are not present
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Corrected on
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Extension cords are 12 gauge or larger and used for temporary use only
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Corrected on
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Perforator interlocks are installed/functioning properly
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Corrected on
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SAF starts are installed where needed
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Corrected on
Employee health (PPE/Environmental)
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Adequate shaded areas and fresh water is provided
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Corrected on
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Cold weather/Cut resistant/Insulated rubber/Heat resistant gloves are available
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Corrected on
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Ear plugs/muffs are available and being worn
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Corrected on
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Face shields/Welding hoods are available and being worn
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Corrected on
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Location for heat gloves/purging PPE is clear
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Corrected on
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Location for personal items has been identified (Water bottles, coats, etc.)
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Corrected on
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Proper clothing/footwear is worn and enforced
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Corrected on
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Proper lifting techniques are observed
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Corrected on
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Purging hoods/jackets are available and worn
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Corrected on
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Rain gear is available
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Corrected on
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Restrooms are adequate and nearby
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Corrected on
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Safety knives are available and used
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Corrected on
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Safety Glasses/Safety vests/Hi-vis shirts are available and being worn
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Corrected on
Equipment (Guards/Compactors)
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Bag/Trash/Cardboard compactors are functioning properly
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Corrected on
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Bandsaw guarding is adequate/adjusted correctly per part
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Corrected on
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Bench grinder tongue guard/tool rest is adjusted properly - 1/8"
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Corrected on
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Bench grinder wheel has been ring tested/replaced yearly
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Corrected on
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Bench grinders/Drill presses are adequately guarded and securely fastened
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Corrected on
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Corrugator/Extruder drive motor, gear box guarding is adequate
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Corrected on
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Guarding on auxiliary equipment is adequate
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Corrected on
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Melt pump/Screen changer guarding is adequate
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Corrected on
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Perforator/Coiler guarding is adequate
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Corrected on
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Purging guard is in place, adequate and being used
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Corrected on
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Spare/Extra equipment is stored properly in their designated location
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Corrected on
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Waterbath/Haul-off/Pulling wheels guarding is adequate
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Corrected on
Flammables/Fire safety/First aid
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Accident investigation forms/procedures are posted and current
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Corrected on
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Acetylene and Oxygen tanks are properly secured/stored 25' apart
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Corrected on
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All flammable items are stored in cabinets/containers (Spray paint, gasket spray, rags, etc.)
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Corrected on
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Evacuation plan/meeting place for emergencies is understood/posted/adequate
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Corrected on
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Eye wash station and sharps container are available and current
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Corrected on
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Fire extinguisher checklist is being filled out
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Corrected on
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Fire extinguishers have been inspected monthly/annually
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Corrected on
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Fire extinguishers are present/current and adequately placed (including a Class "C" extinguisher in MCC room
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Corrected on
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First aid kits/blood borne kits/extra bio hazard bags are available and adequate
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Corrected on
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First aid tracking is being completed
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Corrected on
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Flammable cabinets have been installed
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Corrected on
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Fuel tank berming is adequate and protected against damage
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Corrected on
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GHS/HAZ COM chemicals are communicated
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Corrected on
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Heaters are free of flammable items nearby
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Corrected on
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Liquid propane tanks are stored properly
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Corrected on
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Oil is stored in an adequate area with adequate spill containment for bulk oil
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Corrected on
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Plant address/Poison control numbers/911 numbers (hospital, fire and police) are posted
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Corrected on
Fleet Equipment (Forklifts/Trucks/Pickups/Trailers)
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All forklift operators are certified
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Corrected on
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All vehicles/forklifts are parked properly and in adequate areas
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Corrected on
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Forklift attachments/masts are adequate/not bent/free of cracks/defects
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Corrected on
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Forklift training records and checklists are saved
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Corrected on
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Forklifts/trailers/trucks/pickups tires appear to be in good condition
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Corrected on
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Forklift/truck/pickups glass is clean/clear/free of breaks/cracks
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Corrected on
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Lanes are adequate width for loading/traffic flow
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Corrected on
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Lights/brake lights/flashers/horns are functional
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Corrected on
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Liquid propane tank alignment pin is ok and tank is secured properly
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Corrected on
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Safety chains are present on trailers where needed
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Corrected on
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Seats/seat belts are in good condition and functional
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Corrected on
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Trailer jacks/wheel chocks are available and used for docked vans
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Corrected on
General (Tools/Brooms/Inventory/Air wands)
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Air wands/hoses are approved
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Corrected on
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All doors are functional
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Corrected on
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Brooms/shovels/garbage cans/ladders are in their place
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Corrected on
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Brooms/shovels/hand tools have factory handles that are not broken/modified
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Corrected on
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Center cores are stacked neatly and not scattered
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Corrected on
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Cleaning stations are adequately placed (easy to locate) and have a consistent layout (same tool same spot)
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Corrected on
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Dust and drainage is controlled adequately
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Corrected on
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Extra pallets/boxes/unused sock rolls have been put away in their assigned location
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Corrected on
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Fittings area is reasonably organized and labeled
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Corrected on
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Garbage cans have a handle and are on a dolly or have wheels (no 55 gallon barrels)
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Corrected on
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Lifting straps/lifting chains are in good condition and have inspection tag attached
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Corrected on
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Loose hardware/straps/chains/un-used hand tools have been picked up
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Corrected on
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Obsolete items/un-used equipment have been moved to the red tag area
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Corrected on
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Pipe is reasonably and safely stacked
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Corrected on
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Ratchet straps/Chains are in good working order with no defects
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Corrected on
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Spare parts are organized/labeled in cabinets or on shelves
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Corrected on
Mobile stairs/Stairways/Handrails/Walkways/Racking
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All handrails are adequate (corrugator, mezzanine storage) and secure (200#)
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Corrected on
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Designated walkways/stairways are clear of debris/unobstructed/clearly marked
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Corrected on
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Items stored on mezzanines/pallet racking is secure/stacked straight
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Corrected on
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Mezzanine storage/Steel racks/Pallet racking is labeled with 3" x 5" load limits
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Corrected on
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Mobile stairs are in good condition/straight/unmodified and available
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Corrected on
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Pallet racking/Steel racking is anchored properly and are sufficient to hold current load
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Corrected on
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Stairways meet OSHA standards
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Corrected on
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Tie down ladders are available for rack trailers
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Corrected on
Visual controls (Signage/SOP's/Procedures/LOTO)
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Exit signs are adequately placed
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Corrected on
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Fuel tanks have adequate signage
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Corrected on
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Kanban is being used/replenished for inventory items (screens, tape, fittings, etc.)
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Corrected on
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Ladder inspection SOP's are next to all ladders
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Corrected on
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Location of hand tools/cleaning supplies are visible (color coding, shadow boards, etc.)
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Corrected on
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Location for spare equipment has been identified (sock tubes, perforators, string stands, etc.)
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Corrected on
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LOTO is being followed per tracking log
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Corrected on
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LOTO materials are available/adequate/current
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Corrected on
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LOTO procedures are adequate/accurate/posted on or near all equipment
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Corrected on
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OSHA posters are posted and current
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Corrected on
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Purging chains and signs are installed and used
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Corrected on
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SDS book is available and adequate
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Corrected on
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Sharps log is present
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Corrected on
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Signage is clearly posted for customers
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Corrected on
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Site map is complete and adequate
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Corrected on
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Speed limits are posted and followed
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Corrected on
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Zones are color coded (including tools, garbage cans, etc.)
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Corrected on
Completion date
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Expected completion date for "At Risk and Repeat" items
