Health and Safety Systems Audit

Does the location have a written Emergency Action Plan that is reviewed annually

Procedures for employees who must remain behind for critical operations

Assigned duties for employees who are responsible for rescue

Assigned duties for employees responsible for medical care

Established procedures for employees to report emergencies

Can the alarm be distinguished from other background noise sources

Are specific employees assigned to alert employees who may not recognize the alarm

Are the audible alarms different for evacuations, shelter-in-place, ammonia leak, etc.

Does your emergency notification system include a verbal notification to employees (i.e. radio or intercom)

Are emergency notification systems maintained and tested regularly per NFPA or Manufacturer's Recommendations

Are employees with specific functions within the emergency plan trained in correct methods of performing these duties

Are employees trained on evacuation routes at time of hire

Are employees retrained when the plan or their duties change

Does the plant have an annual building evacuation and severe weather drill

Is it documented on the "Emergency Drill Report and Assessment", with feedback collected and corrective actions put in place

Are sprinkler impairment procedures in place and are they followed

Is annual fire extinguisher training provided, documented for applicable personnel, and include hands-on practice

Are emergency exit routes and discharge areas illuminated during power outage and hours of darkness

Does the location have a written Permit Required Confined Space Entry Program

Is the Permit Required Confined Space Entry Program reviewed annually

Does the plant have a list of all confined spaces and is it accurate, up to date, and reviewed annually

Does the plant have a written confined space hazard survey for each space on file, and is it accurate, up to date and reviewed annually

Are problems encountered during the entry noted on the permit and corrected before subsequent entries are authorized

Are procedures implemented to reclassify permit required confined spaces by eliminating hazards

Review 5 random reclassification documents - all must be accurate to receive a positive score

Are air sampling instruments properly calibrated and bump tested before each use with calibration gas that is not expired

Are permit spaces tested and monitored to determine if the space is safe for entry and to ensure that conditions remain acceptable for the duration of the job

Are emergency/rescue procedures implemented and an attendant available outside the space for the duration of the entry

Have simulated rescues taken place on an annual basis

Is annual training on using the gas meters in the facility provided to confined space entry personnel, emergency response personnel, etc.

Are Confined Space permits filled out completely for each entry

Are completed permits retained for a minimum of 1 year

Are duties and responsibilities identified for employees who have active roles in entry operations

Has annual training been provided and documented for all Rescue Personnel as required by their job function and responsibility

Have all affected employees been trained per the requirements in the SugarCreek Permit Required Confined Space Entry Program

Has the plant developed a plan for emergency rescue and medical treatment

Is there an annual review of the program including job site compliance to determine effectiveness and identify deficiencies

Are any deficiencies noted resolved through documented means including training

Does the plant coordinate the activities of contractors hired to perform work in a permit required confined space

Is the facility operated by someone with at least a current certification in first aid/CPR/AED on all shifts

Does the plant keep an OSHA 300 log for all occupational injuries and illnesses

Has the OSHA 300 log been completed and signed for the previous five years and are they retained

Is the OSHA 300A Summary Form posted from February 1 - April 30 of each year

Are entries logged within seven calendar days of receiving information that a recordable injury or illness has occurred

Do plant personnel understand the criteria for logging injuries and illnesses and have a copy of the OSHA Recordkeeping Policies and Procedures Manual readily accessible

Is the Recordable Incident form completed for each recordable injury

Is the Recordable Incident form numbered to correspond with each entry on the OSHA 300 log

Do plant personnel understand the OSHA reporting requirements for fatalities ,hospitalizations, amputations or loss of an eye

Do plant personnel understand who has access, upon request, to review the OSHA 300 log and OSHA 301 forms (Recordable Incident form)

Do plant personnel maintain calendars to track restricted and lost days

Is all documentation present for case file #1

Is all documentation present for case file #2

Is all documentation present for case file #3

Do plant personnel understand who has access to employee exposure and medical records

Do plant personnel understand the time frame (15 days) within which to provide access to medical records

Does the plant have a form for employees to fill out when requesting access to records in order to ensure that employees are provided the information within the standard time limits

Does the plant have a posting or other means to communicate employee's rights to access their medical records and is the information up to date

Are new employees informed of their rights to access their medical files and is this documented

Are existing employees informed of their rights to access their medical files on an annual basis and is this documented

Does the plant have a written control program for BBP

Does BBP training contain an accessible copy of the BBP regulation and exposure control plan

Does BBP training contain BBP epidemiology and symptoms

Does BBP training contain BBP modes of transmission

Does BBP training contain recognizing high exposure risk tasks

Does BBP training contain universal precautions, engineering & work practice controls ( to include specifics on housekeeping & laundry practices, products/PPE to be used, sharp handling/disposal, etc.)

Does BBP training contain PPE (types available, limitations, proper use, location, decontamination/disposal, etc.)

Does BBP training contain choice of appropriate PPE for situation

Is the BBP training Hepatitis B vaccination program consistent with CDC guidelines

Does BBP training program contain proper use of biohazard signs, labels and bags

Does BBP training allow for adequate time for Q&A

Do the training records contain the date of training, summary of training, names & qualifications of persons conducting training, names & titles of persons attending training

Are training records maintained for three years , along with a tracking log of BBP individuals trained annually with Hepatitis B forms

Does the plant provide at no cost appropriate PPE to respond to a BBP incident

Does the plant assure appropriate PPE in proper sizes is issued and is readily accessible to employees

Has HBV been made available after training & within 10 days of initial assignment to employees who have occupational exposure

Have employees who have declined the HBV signed a declination form initially and annually

Has the plant established & maintained an accurate record for each employee with an occupational exposure

Has the plant established a sharp's log and does it include the type and brand of the device involved, department where the incident occurred and an explanation of how the incident occurred

Are noise level readings repeated whenever a change in process, equipment, or controls increase exposure

Has each employee who is exposed to noise at an 8-hour TWA of 85 decibels been notified of the results of the noise survey

Are feasible engineering/administrative controls utilized to reduce sound levels to the permissible levels

If controls fail to reduce sound levels, is PPE provided to each exposed employee

Has an audiometric testing program been established for employees exposed to a TWA of 85 decibels

Are audiometric tests performed by a technician who is responsible to an audiologist or physician

Has a baseline audiogram been established within six months of exposure (or 12 months if mobile testing unit is used)

Are annual audiograms obtained and submitted to an audiologist within one month of the date of the test and compared to baseline for all employees in the hearing conservation program (check report to ensure results are compared to baseline results)

Are employees retested within thirty days if an annual audiogram shows a standard threshold shift (STS)

Are employees notified of an STS in writing within 21 days of determination and referred for a clinical audio logical evaluation or otological examination

Is hearing protection made available to all employees who require it

Is the hearing protection attenuation evaluated against the noise levels in the plant

Does the plant have annual hearing conservation training

Does the training include effects of noise on hearing

Does the training include the purpose of hearing protectors - advantages, disadvantages, and attenuation of various types

Does the training include instruction on selection, fitting, use, and care

Does the training include the purpose of audiometric testing and an explanation of the test procedure

Does the plant make available a copy of the standard

Are noise exposure measurements records retained for two years

Are audiometric test records retained for duration of the employee's employment

Are employees showing a STS (an average of 10 dB decrease from baseline in the2K, 3K and 4K frequencies (Hz) and a change of 25 dB or more from audiometric zero (averaged at 2000, 3000 and 4000 Hz) recorded on the OSHA 300 log

Does the plant have a written Control of Hazardous Energy Program

Is the Control of Hazardous Energy program reviewed annually

Are procedures developed, documented, and utilized for the control of potentially hazardous energy for each piece of equipment/machinery

Are the energy control procedures reviewed annually to ensure that they are all present, accurate and up-to-date

Are locks only used to lockout equipment, of the correct color (stated in policy)

Does the plant conduct an annual inspection of the energy control procedures to assure that the procedures and the requirements of the standard are being followed

Are 100% of authorized lockout personnel audited annually and documented

Is the annual inspection performed by authorized employee(s)

Does the annual inspection include date, employees included in inspection, person performing inspection, equipment/machinery on which the inspection occurred

Has annual training been conducted to assure that the purpose and function of the LOTO program is understood by authorized and affected employees

Is retraining provided/documented when assignments or processes change (i.e. new equipment prior to start-up)

Is a list of authorized lockout employees maintained with annual training, annual audits, and lock serial numbers tracked

Are written procedures developed for all exceptions to the lockout program

Do the exception procedures list work procedures for each task in detail

Are all relevant employees trained on the lockout Minor Exceptions

Tags are not being utilized in lieu of locks, where applicable

Administrative lock system utilized in accordance with lockout policy

Procedures developed for removal of a LOTO device before energy is restored and procedures require the LOTO device be removed by the employee who applied it

Are procedures written for removal of a LOTO device when an employee has left the plant and are the forms being used to document application of this process

Are group LOTO procedures utilized

Are written specific procedures used during shift or personnel changes to ensure continuity of LOTO protection

Does the plant have a written Machine Guarding Program

Is the Machine Guarding program reviewed annually

New equipment approval completed and concerns addressed before start-up of equipment

Has a machine guarding checklist been performed on all equipment

Do plant personnel conduct housekeeping audits of the interior and exterior of the plant on a scheduled basis

Are the housekeeping audits documented

Are ladders inspected regularly and meet safety requirements

Are employees trained on the proper use of ladders

Does the plant have a Fall Protection and Prevention Program

Is the Fall Protection and Prevention Program reviewed annually

Is training being performed and documented as required in the policy (slip/trip/fall, harness use/inspection, etc.)

Fall protection for roof in place and annually reviewed/certified per manufacturer's recommendations

Is fall protection equipment inspected annually by a competant inspector

Are scaffolds installed and inspected daily by a qualified person

Have all employees working on scaffolding received training from a qualified person

Have they been provided harnesses/lanyards where required

Does the plant have a written Powered Industrial Truck Program

Is the Powered Industrial Truck Program reviewed annually

Is there a licensing program for all powered industrial trucks at the facility and does the process include formal classroom training/quiz, hands-on training of equipment (employee is to drive), and evaluation of the powered industrial truck driver

Is refresher training provided every 3 years (and documented) or when an unsafe operation is recognized, accident or near miss incident, evaluation indicates need, different equipment is introduced or a change in workplace conditions

Have safe operating rules been established and enforced

Are trucks taken out of service when found to be unsafe or in need of repair

Is the filling of fuel tanks prohibited when the engine is running

Are repairs made only by authorized personnel

Does the plant have a written Hazard Communication Program

Is the Hazard Communication Program reviewed annually

Does the plant have a list of all hazardous materials that can be referenced to a SDS

Does a SDS exist for all hazardous materials

Are SDS's accessible at all times for employee's use

Do employees know how to obtain copies of the SDS

Do employees know how to read SDS's and find appropriate safety information

Are employees trained on hazardous chemicals, hazard communication, the new Global Harmonization requirements, and Safety Data Sheets in their work area upon initial assignment and annually thereafter and is the training documented

Are they trained whenever a new hazard is introduced to the work place

Is the location of the written HAZCOM program communicated to all employees; Are employees trained on methods and observations that may be used to detect the presence or release of hazardous chemicals

Are all personnel trained on common plant-wide chemicals (i.e. ammonia, alpet, foot foamer, dry quat, etc.)

Are employees retrained as necessary to emphasize this information (i.e. after an incident, lessons learned, or new info.)

Does the plant have a written Personal Protective Equipment (PPE) Program

Is the Personal Protective Equipment (PPE) Program reviewed annually

Has the plant conducted an annual hazard assessment to determine whether hazards are present requiring the use of PPE

Based upon the assessment, has the plant selected appropriate and properly fitting PPE

Does the plant routinely check that defective or damaged PPE is not being used

Does the plant train employees on the use of PPE

Does the plant retrain when necessary

Does the plant have a written Electrical Safety Program

Is the Electrical Safety Program reviewed annually

Are qualified and unqualified persons trained on the policy upon assignment and at the prescribed frequency as outlined in the program with supporting documentation

Are electricians or other qualified personnel trained on lockout

Has an Arc Flash Study been conducted

Do all open items have an action plan

Has the study been updated for any electrical changes/projects that have occurred at the location

Are electrical/high voltage maintenance gloves tested and inspected according to manufacturer recommendations (i.e. every 6 months)

Are all electrical testing equipment and meters inspected for external defects and damage prior to use, calibrated annually, provided by the company, and category III rated or higher

Do personnel who are to work on exposed live parts over 600 volts or (voltage level determined by plant) perform the 3-point test prior to performing the work

Does the plant have a Hot Work Program

Is the Hot Work Program reviewed annually

Does the plant have a cutting/welding (Hot Work) permit system

Are the permits filled out completely and approved prior to welding or cutting

Are fire watches provided for all required permit work

Are Hot Work permits retained for 1 year after work completion

Has the facility completed hexavalent chromium industrial hygiene studies on welding activities as required by OSHA

Are all appropriate personnel trained on cutting/welding procedures and fire watch procedures upon assignment and annually thereafter and is this training documented

Are employees trained on the proper PPE required to use while welding, cutting and/or brazing

Have personnel performing Hot Work received HAZCOM training on hexavalent chromium and welding fumes

Does the plant have a written Contractor Health and Safety Program

Does the plant have a master list of "approved" contractors

Are the contractors audited on a frequent basis

Are they documented

Are contractor work permits being utilized for contractor work

Audit 3 contractor work permits that were completed within the last 14 days - Are they completed in their entirety

Are the contractors trained on the SugarCreek contractor policy before performing work or services at the facility

Do the contractor supervisors or SugarCreek designated trainer train the respective contractors on the SugarCreek contractor policy

Is there documentation to verify that the training occurred

Are employees trained not to use compressed air to blow off selves and clothing

Is it documented

Do the air nozzles have the required OSHA nozzles to reduce pressure maximum of 30psi

Are employees required to wear eye protection while using compressed air

Are all compressed air lines outfitted with the appropriate connectors (i.e no worm-style clamps etc.)

Does the facility conduct rack inspections on a frequent basis

Does the facility have a system to repair or replace damaged racks

Are all emergency eyewash / showers inspected at least weekly

Are the inspections documented

Are all operational x-ray machines registered with the state, if applicable

Are all non-operational x-ray machines registered with the state, if applicable

Is training conducted (all training materials) in employee's native language where applicable or a translator provided

Are quizzes utilized for appropriate training sessions or hands-on demonstration

If translator is used, are they signing off on all documents they were utilized for

Is the Safety Footwear Authorization form maintained and up-to-date

Does the plant have a safety committee

Does the committee consist of employees from multiple shifts

Does the committee consist of hourly employees

Does the committee meet at least monthly

Is the meeting documented to include topics covered and employees in attendance

Plant has emergency evacuation routes posted in common areas

Are emergency contact numbers up-to-date and posted

Does the plant control the accumulation of flammable and combustible waste materials so they do not contribute to a fire emergency (i.e good housekeeping, 5S, good storage)

During audit tours were exit routes clear

Are two exits readily accessible for each occupant in required rooms

Are exit doors and doors leading to exits side-hinged type

Do rooms with more than fifty occupants have doors that swing in the direction of travel

Do all exit doors have free egress

Are exit routes clearly marked

Are exit routes designed to prevent travel through high-hazard areas

Do exit routes meet the minimum width of 28 inches and height of 90 inches

Do emergency exits discharge to safe areas

Are all exits marked by signs with lettering 6 inches in height

Are all doors that could be confused as an exit marked with a sign " NOT AN EXIT " or signage indicating the room name (eg. Conference room)

Are all permit required confined spaces posted with appropriate signage

Is required equipment (air sampling instruments, ventilation equipment, PPE, lighting, communication equipment, barriers and rescue devices) available and maintained

Are adequate first aid/AED supplies on hand and centrally located

Is the OSHA poster appropriately displayed in a conspicuous place in the plant

Are biohazard labels visible & firmly attached to appropriate containers of regulated waste

Are biohazard labels florescent orange or orange-red with letters or symbols in a contrasting color

Are storage racks securely fastened to the floor to prevent accidental tip-overs

Are the facility's storage racks in good repair

Flexible cords are not used as a substitute for fixed wiring

Are employees in the facility wearing hearing protection, if required in their area

Is the Hearing Conservation standard posted in the workplace

Are multiple energy source equipment/machinery isolation points clearly identified and marked

Were any LOTO violations observed during the tour of the facility

Have one or more machine guarding methods been provided to protect employees from hazards such as those created by point of operation, ingoing nip points, rotating parts, flying chips and sparks

Are guards affixed to the machine where possible and secured elsewhere if attachment to the machine is not possible

Is the machine guard designed so as not to create a hazard

Are special tools provided for placing or removing material without the operator placing a body part in the danger zone of the machine

Are precautions in place to assure tools are not used as a substitute for guarding

Machine guards should not be easily removed and must require a specialized tool to remove them or be interlocked

Have revolving drums, barrels, and containers been guarded by an interlocked guard so the equipment cannot revolve unless the guard is in place

Have fan blades less than 7 feet above the workstation been guarded

Have conveyors less than 7 feet above the workstation been underguarded

Are fan guards provided with openings no bigger than one-half inch

Does the guarding on pedestal grinders meet OSHA requirements

Are all machines that are designed for a fixed location securely anchored to prevent them from moving during use

Are working/walking surfaces kept clean

Are working/walking surfaces kept dry where practical

Are non-slip surfaces used in critical areas

Are standard handrails and toe boards used to protect floor changes, ditches, tanks, etc., with a drop of four feet or more

Are standard handrails and toe boards used to protect any drop where a hazard exists at the bottom

Are covers used to protect floor openings and hatchways

Are swing gates used to protect ladder openings in floors

Are standard handrails and toe boards used to protect all open sides of work platforms four feet from the floor

Are standard handrails and toe boards used to protect all open sides on work platforms to dangerous tanks or equipment

Are employees who work on platforms standing in a proper safe position

Are load rating limits marked and posted on top of mezzanines, storage areas, and similar surfaces

Is rail, roller, picket fence, half door or equivalent in place when a floor opening with a drop of four feet or more is not in use

Are chutes through walls protected

Are windows where the bottom opening is less than three feet above the floor guarded by a railing or slat <br>

Stairways less than 44" wide - Both sides enclosed - one rail preferably on the right side descending

Stairways less than 44" wide - One side open - rail on open side

Stairways less than 44" wide - both sides open - rails on both sides

Stairways 44" to 88" wide - rail on each side

Stairways greater than 88" wide - rail on each side and intermediate midway of width

Winding stairs - are they equipped with a rail offset to prevent walking on portion treads with less than 6" of width

Are ladders not in use stored horizontally or chained/ latched to a fixed object

Are ladders used by one person at a time

Are ladders not placed in front of door openings unless door is locked or guarded

Are ladders with missing rung, steps or cleats removed from service

Fall limiters in use for any work above 4 ft and below 18.5 ft

Are skylights protected in such a way to prevent a load of 200 lbs or greater from falling into them (openings should not be more than 4 inches in length or 2 inches in width)

Are scaffolds designed to hold more than four times their maximum intended load

Are scaffolds not moved horizontally while in use or occupied

Are scaffolds protected by rails and toe boards if more than ten feet above ground

Are mobile platforms at least 20" wide

Fixed Stairs riser height and tread width should be uniform, 22 inches wide (minimum), angle between 30 and 50 degrees, vertical clearance 7 feet, and tread less than 9 inches wide - risers must be open

Is the industrial truck of the proper classification for its operating environment

Are all industrial trucks equipped with an overhead guard, where applicable

Are seatbelts being worn, where applicable

Are unauthorized personnel prohibited from riding on powered industrial trucks

Are wheel chocks, jack stands, dock-locks, or other means of securing trailers utilized to prevent the trailer from moving away from the dock or upending during loading/unloading

Is there sufficient headroom under overhead installations, lights, pipes, etc. to prevent the PIT or loads from striking them

When lifting personnel on the forks is a safety platform equipped with standard guardrail, midrail, toeboard used; is the safety platform secured to forks; does the operator of the lift remain at the controls at all times; are employees in the safety platform equipped with a safety harness

Are only stable and safely arranged PIT loads handled

Are only loads within the rated capacity of the PIT handled

Are PIT operators not wearing any noise or audio headphones

Are operators not using any mobile device while operating a PIT

Are PITs inspected prior to each shift

Are bulk storage tanks, totes, barrels, drums and other chemical containers identified as to their contents according to GHS requirements

#1 - Does selected chemical have an SDS printed for employee awareness

#2 - Does selected chemical have an SDS printed for employee awareness

#3 - Does selected chemical have an SDS printed for employee awareness

Is appropriate eye protection being used and is in good condition to protect against flying particles

Is appropriate eye protection being used and is in good condition to protect against molten metals

Is appropriate eye protection being used and is in good condition to protect against liquid chemicals

Is appropriate eye protection being used and is in good condition to protect against acids or caustic chemicals

Is appropriate eye protection being used and is in good condition to protect against chemical gasses or vapors

Do the employees have the appropriate PPE for the task being performed

Are appropriate protective helmets being worn and in good condition where there is danger of falling objects

Are appropriate equipment items worn and in good condition to protect the employees torso against hazards such as (heat, cuts, impact, splash/sparks, chemicals

Is appropriate foot/leg protection being used and in good condition to protect against falling or rolling objects, objects that pierce the sole, or electrical hazards

Is arm/hand protection being worn and in good condition when hands are exposed to absorption of harmful substances

Is arm/hand protection being worn and in good condition when hands are exposed to severe cuts (i.e sharpening and handling equipment blades - slicers, packaging machines, etc.)

Is arm/hand protection being worn and in good condition when hands are exposed to abrasions

Is arm/hand protection being worn and in good condition when hands are exposed to punctures

Is arm/hand protection being worn and in good condition when hands are exposed to chemical or thermal burns

Is arm/hand protection being worn and in good condition when hands are exposed to harmful temperature extremes

Are all electrical panels labeled by a Nationally Recognized Testing Laboratory (UL or FM )

Are electrical disconnecting means identified as to voltage & function

Are electrical panels installed with sufficient clearance to allow safe repairs

Are all electrical panels properly labeled as to what each breaker controls

Are all electrical live parts with over fifty volts guarded

No cracked or missing electrical receptacle box covers

Is the fume extractor in place, in working condition, and filter being maintained per manufacturer's instructions

Are welding shields/curtains used to prevent exposure to arc's where needed

Is the employee/contractor performing all Hot Work in accordance to the Hot Work Program

Are all gas cylinders chained to a fixed object or secured to prevent accidental tip over

Are all gas cylinder valves closed when not being used

Do all gas cylinders not in use have a cap on them

Are gas cylinders stored in a well-protected, well-ventilated, dry location and at least 20 ft. from highly combustible materials

Propane cylinders stored properly so that relief valve is not blocked

Are oxygen cylinders separated from fuel-gas cylinders or combustible materials a minimum distance of 20 ft. or by a noncombustible barrier at least 5 ft. high having a fire-resistance rating of at least one half hour

Are gas cylinders transported in a secured vertical position

Are all emergency eyewash / showers maintained in operational condition

Are the emergency showers / eyewash accessible and free from clutter

Are emergency showers / eyewash units located within immediate area for battery charging stations

Where the eyes or body of employees may be exposed to corrosive or hazardous materials, are suitable facilities for quick drenching or flushing of the eyes and body readily available within the work area for immediate use

Are all employees who are identified through their job functions as outlined in the Safety Footwear Program wearing safety toed footwear in accordance with the program

Is the EHS Policy Statement posted in a conspicuous place within the facility

#1 - Interview one trained confined space entry employee to determine their knowledge of hazardous atmospheres

#2 - Interview one trained confined space entry employee to determine their knowledge of hazardous atmospheres

Did employee #1 know the lockout procedure for the machine they lockout

Did employee #2 know the lockout procedure for the machine they lockout

Is employee #1 trained on the chemicals they commonly use

Is employee #2 trained on the chemicals they commonly use