Integrated Safety Audit

• Document No.

• Audit Title

• Client / Site

• Conducted on

  Date

• Prepared by

• Location
  Address

• Personnel

• Department

  Select Extrusion Extrusion Prep Maintenance Remelt Fabrication Pack Load Ship

  • Extrusion
  • Extrusion Prep
  • Maintenance
  • Remelt
  • Fabrication
  • Pack Load Ship

• Area within department

• Auditor

• Audit Date and Time

  Date

Confined Space

• Answer the following questions for each Confined Space

Open Confined Space

• Is the confined space permit completed correctly?

  Yes

  No

  N/A

• If possible, is rescue equipment set up at the job site?

  Yes

  No

  N/A

• Is the calibration log completed correctly? (Observe the calibration being performed)

  Yes

  No

  N/A

• Is the confined space center clean and organized?

  Yes

  No

  N/A

• Do the calibration gas cylinders have more than 50 psi of pressure?

  Yes

  No

  N/A

• Is the inspection color coding current on retrieval devices and tripods? (Green for 1st six months, Yellow for 2nd six months)

  Yes

  No

  N/A

• Locate several confined spaces. Are the confined space signs visible/legible?

  Yes

  No

  N/A

• Interview team members who enter confined spaces. Are they aware of the need to complete an entry permit and check the air before entering?

  Yes

  No

  N/A

• Are all monitors present or accounted for?

  Yes

  No

  N/A

• Has the space been monitored for atmospheric hazards?

  Yes

  No

  N/A

• If the space requires ventilation, is the ventilation equipment being used properly?

  Yes

  No

  N/A

• Is the confined space assessment, entry procedure, rescue procedure, MSDS sheets (if applicable) and Hot Work Permit (if applicable) attached to the confined space permit?

  Yes

  No

  N/A

• Is the sample probe used so that the monitor doesn't have to be lowered into the space?

  Yes

  No

  N/A

• Does the probe contain an inline filter?

  Yes

  No

  N/A

Electrical Safety

• Answer the following questions for Electrical Safety

Open Electrical Safety

• Are electricians performing per shift glove testing?

  Yes

  No

  N/A

• Are the electricians using the correct PPE for the task?

  Yes

  No

  N/A

• Has a safe work zone been established?

  Yes

  No

  N/A

• Are multimeters checked for proper operation before and after checking for de-energization?

  Yes

  No

  N/A

• Are electricians using insulated tools to work in close proximity to energized conductors?

  Yes

  No

  N/A

• Are tools and PPE clean and dry?

  Yes

  No

  N/A

• Are all cords and power tools being used GFCI protected?

  Yes

  No

  N/A

• Do cords and power tools have the proper inspection color coding? (1st qtr - Green, 2nd qtr - Blue, 3rd qtr - Yellow, 4th qtr - Red)

  Yes

  No

  N/A

• Are the electricians using the proper PPE for servicing and maintaining battery storage systems?

  Yes

  No

  N/A

• Is the proper clearance maintained in front of and to the sides of electrical panels?

  Yes

  No

  N/A

• Are insulated tools, rubber hose, blanket and gloves within the inspection window?

  Yes

  No

  N/A

• Are electrical cabinets closed or guarded when craftsman leaves the area?

  Yes

  No

  N/A

• Are cabinets in good condition? (Not damaged, no holes or openings and all screws in place)

  Yes

  No

  N/A

• Are all power tools, extension cords and plugs free from obvious damage?

  Yes

  No

  N/A

• Are disconnects marked to identify the specific equipment that they supply?

  Yes

  No

  N/A

• Extension cords are not used in place of permanent wiring?

  Yes

  No

  N/A

• Are electrical boxes, conduit, and other enclosures closed so that you cannot see wires?

  Yes

  No

  N/A

Free Moving Mobile Equipment

• Answer the following questions having to do with Free Moving Mobile Equipment

Open Free Moving Mobile Equipment

• Golf Carts, Forklifts, Front End Loaders...... Is a documented per operational inspection available for this shift and is it completed properly?

  Yes

  No

  N/A

• Do observations confirm that all operators are wearing seat belts when provided?

  Yes

  No

  N/A

• Does equipment come to a complete stop at posted intersections and blind corners?

  Yes

  No

  N/A

• Are horns sounded when approaching pedestrians from the rear and at blind intersections?

  Yes

  No

  N/A

• Are loads on fork lifts being carried in a manner that does not obstruct forward vision?

  Yes

  No

  N/A

• Do vehicle operators look while backing?

  Yes

  No

  N/A

• Is equipment turned off and parking brake set when operator is more than 25' from the vehicle and anytime the vehicle is out of view?

  Yes

  No

  N/A

• Does mobile equipment stop five minutes before and after the start of the shift? (EOWEO shifts)

  Yes

  No

  N/A

• Are Team Members walking in designated and/or protected walkways and not in roadways?

  Yes

  No

  N/A

• Select several vehicles. Check the PM sticker and hour meter. Is the vehicles PM current?

  Yes

  No

  N/A

• Is the vehicle's PM current?

  Yes

  No

  N/A

• Are the vehicle's headlights turned on whenever the vehicle is being used (day or night)?

  Yes

  No

  N/A

• Are vehicles being operated in designated aisle ways and not in pedestrian walkways?

  Yes

  No

  N/A

• Are designated walkways clear of obstructions such as racks?

  Yes

  No

  N/A

• Are stop signs and mirrors provided at intersections and blind corners?

  Yes

  No

  N/A

• Are the mirrors clean and in good condition?

  Yes

  No

  N/A

• Are they adjusted properly?

  Yes

  No

  N/A

• Material is not stacked in a manner to reduce vehicle operation or pedestrian visibility at corners of intersections?

  Yes

  No

  N/A

• Visually inspect road and traffic ways. Are they in good condition and free of damage, clutter and oils, water and lubricants that may affect the safe operation of mobile equipment?

  Yes

  No

  N/A

• Are any golf carts, and tricycles observed provided with an orange flag?

  Yes

  No

  N/A

Lockout Tagout Verify

• Answer the following questions regarding Lockout Tagout Verify

Open Lockout Tagout Verify

• Are red and white danger tags legible?

  Yes

  No

  N/A

• If lock box was used, were yellow danger tags attached to the lock box locks?

  Yes

  No

  N/A

• Is a lockout procedure available for the equipment being serviced? (If revision is needed, complete corrective action)

  Yes

  No

  N/A

• Are the tags filled out properly? Name, Date, Location...

  Yes

  No

  N/A

• Have the stubs from the yellow tags (attached to the lockbox locks) been placed in the lockbox?

  Yes

  No

  N/A

• Have the stubs from the yellow tags (attached to equipment) been returned to the shift supervisor?

  Yes

  No

  N/A

• Is the lockout procedure posted at the equipment?

  Yes

  No

  N/A

• Are all isolation points tagged or otherwise identified?

  Yes

  No

  N/A

• Did the Team Member properly isolate the equipment?

  Yes

  No

  N/A

• Did the Team Member notify personnel affected by his/her work?

  Yes

  No

  N/A

• Did the Team Member place his/her lock on the energy isolating device?

  Yes

  No

  N/A

• Did the Team Member place his/her red & white danger tag on the energy-isolating device?

  Yes

  No

  N/A

• Did the Team Member test the isolation by attempting to start the equipment?

  Yes

  No

  N/A

• Is Lockout performed when Team Members enter Crane Envelope?

  Yes

  No

  N/A

• At the completion of the task, was the lock & tag removed?

  Yes

  No

  N/A

Machine Guarding

• Answer the following questions related to Machine Guarding

Open Machine Guarding

• Is equipment locked, tagged and verified before machine guarding is removed?

  Yes

  No

  N/A

• If troubleshooting is required while the equipment is energized, is a troubleshooting procedure available?

  Yes

  No

  N/A

• Are two team members present during troubleshooting? (One at the controls)

  Yes

  No

  N/A

• Are all fastening devices in place and secure on the machine guarding?

  Yes

  No

  N/A

• Are the machine guards in good condition?

  Yes

  No

  N/A

• Does the machine guarding pass the AUTO Test? (Unable to reach the hazard by going Around, Under, Through, or Over the guard)

  Yes

  No

  N/A

• Randomly check the operation of light curtains, pressure mats, and interlock switches. Do all function as intended? List equipment reviewed.

  Yes

  No

  N/A

• Interview operators. Do they perform an operational test of light curtains, pressure mats, and interlock switches before the first use on each shift?

  Yes

  No

  N/A

• Are pre-operational inspection books present at light curtains, interlocks, and safety mats?

  Yes

  No

  N/A

• Inspect machine guarding gates. Are bolts in place and securely fastened? ( Tools needed to remove)

  Yes

  No

  N/A

• All operators interviewed understand not to use equipment with damaged, missing or inoperable machine guards.

  Yes

  No

  N/A

• Interview craftspersons . Do they understand that all machine guards must be replaced before equipment is returned to production?

  Yes

  No

  N/A

Fall Prevention/Protection

• Answer the following questions regarding Fall Prevention/Protection

Open Fall Prevention/Protection

• Has the roof work permit been properly completed?

  Yes

  No

  N/A

• Is the white copy posted at the access point and does the yellow copy remain in the book?

  Yes

  No

  N/A

• Is the job being conducted in accordance with the roof work permit?

  Yes

  No

  N/A

• Is temporary guardrail being used around floor openings and holes?

  Yes

  No

  N/A

• If temporary guardrail is unable to be used, is tape being used as a layer of protection? (Must be red danger tape and at least six feet from the floor opening or hole)

  Yes

  No

  N/A

• Are employees using the handrails when climbing or descending stairs?

  Yes

  No

  N/A

• Are the employees maintaining 3-point contact while ascending, descending or working from a ladder? (Six foot ladders and larger)

  Yes

  No

  N/A

• If not maintaining 3-point contact, is the employee wearing fall protection and tied off? (Six foot ladders and larger)

  Yes

  No

  N/A

• Are the ladders stored properly? (Laying down or secured in place)

  Yes

  No

  N/A

• Are the ladders clean and free from grease and debris?

  Yes

  No

  N/A

• Are employees using anchor points provided on cranes?

  Yes

  No

  N/A

• Are employees tying off to the structure before exiting the basket of the highreach or scissors lift?

  Yes

  No

  N/A

• Are Elevated Work Tool & Part Inventory Sheets being used for work which extends into the crane envelope?

  Yes

  No

  N/A

• Does the Fall Protection Cabinet have all items present or accounted for?

  Yes

  No

  N/A

• Do all items in cabinet have the current inspection color code?

  Yes

  No

  N/A

• During loading of trailers, is the net system being used?

  Yes

  No

  N/A

• Does all fall protection equipment (personal) have the current inspection color code?

  Yes

  No

  N/A

Emergency Preparedness and Fire Prevention

• Answer the following questions related to Emergency Preparedness and Fire Prevention

Open Emergency Preparedness and Fire Prevention

• Interview several Team Members. Do they know the emergency phone number and the location of the departments head count area(s)?

  Yes

  No

  N/A

• Are fire extinguisher inspections up to date?

  Yes

  No

  N/A

• Are all fire extinguishers observed un-obstructed?

  Yes

  No

  N/A

• Are hot work permits available and properly completed when performing "hot work" such as welding, cutting, and grinding?

  Yes

  No

  N/A

• Are "charged" fire extinguishers provided at the Hot Work job?

  Yes

  No

  N/A

• Are yellow flammable liquid cabinets free of combustibles such as boxes, rags, gloves, paper, etc.?

  Yes

  No

  N/A

• Are containers for oil and chemical soaked rags provided with a lid?

  Yes

  No

  N/A

• Is the lid tightly closed and has the container been emptied daily?

  Yes

  No

  N/A

• Are locations where flammable and combustible liquids stored posted as "No Smoking" areas?

  Yes

  No

  N/A

• Interview team members. Do they know the location of natural gas automatic shutoffs?

  Yes

  No

  N/A

• Can team members describe the area that the natural gas automatic shutoff isolates?

  Yes

  No

  N/A

• Check several phones. Are they working?

  Yes

  No

  N/A

• In good condition?

  Yes

  No

  N/A

• Provided with emergency sticker?

  Yes

  No

  N/A

• Are blue phone signs posted?

  Yes

  No

  N/A

• Are evacuation maps posted throughout the work area?

  Yes

  No

  N/A

• Check red columns. Is there a fire extinguisher at the column?

  Yes

  No

  N/A

• Is the emergency lighting working? Test.

  Yes

  No

  N/A

• Is the white copy of the Hot Work Permit posted on the board in the Maintenance Shop during the Hot Work operation?

  Yes

  No

  N/A

Housekeeping

• Answer the following questions related to Housekeeping

Open Housekeeping

• Is the shop floor free of debris and trip hazards?

  Yes

  No

  N/A

• Are tools and equipment stored properly?

  Yes

  No

  N/A

• Are trash cans NOT more than 75% full?

  Yes

  No

  N/A

• Are the Safety Circles clear of materials and equipment?

  Yes

  No

  N/A

• Are housekeeping and dust clean procedures posted in the area?

  Yes

  No

  N/A

• Interview operators. Are they aware of the hazards of build-up of aluminum dust?

  Yes

  No

  N/A

• Are operators knowledgeable of clean up procedures?

  Yes

  No

  N/A

• Is appropriate equipment available and being used?

  Yes

  No

  N/A

• Is the area clearly posted with No Smoking signs and red lines?

  Yes

  No

  N/A

• Inspect the work area, surface of equipment and top of equipment and electrical boxes. Are these free from aluminum dust?

  Yes

  No

  N/A

• Is all electrical equipment in repair areas rated as explosion proof?

  Yes

  No

  N/A

• Are aluminum fines disposed of in grounded and labeled drums?

  Yes

  No

  N/A

• Is the tool crib organized?

  Yes

  No

  N/A

Personal Protective Equipment (PPE)

• Answer the following questions related to PPE

Open Personal Protective Equipment (PPE)

• Were all employees observed wearing hearing protection properly?

  Yes

  No

  N/A

• Were all employees observed wearing safety glasses, a hard hat, and approved foot protection?

  Yes

  No

  N/A

• Select several employees and review the fit of their safety glasses. Are they wearing side shields?

  Yes

  No

  N/A

• Do the glasses fit the employee well? (The glasses should fit close to the face with very small spaces on the sides and under the eyes.)

  Yes

  No

  N/A

• Are Hard Hats clean and free of damage?

  Yes

  No

  N/A

• Were all team members observed handling metal, wearing gloves?

  Yes

  No

  N/A

• Are the employees wearing the appropriate PPE for the task?

  Yes

  No

  N/A

Miscellaneous

• Answer the following Miscellaneous questions

Open Miscellaneous

• Randomly select some work areas and locate secondary chemical containers. Does each container have a legible HMIS/NFPA Hazcom label?

  Yes

  No

  N/A

• Randomly select work areas that use Mallets. Check for "mushroomed" heads, cracked handles and any other damage. Are the mallets in serviceable condition?

  Yes

  No

  N/A

• Are all safety signs clean and readable?

  Yes

  No

  N/A

• Observe team members handling metal. Are their hands clear of potential pinch points between the ends of the metal, between the rollers and the metal, between slings and metal and between racks and metal? List the areas reviewed.

  Yes

  No

  N/A

• Is metal banding from logs disposed of properly?

  Yes

  No

  N/A

• Is it not permitted to build up and there is no banding lying about the floor?

  Yes

  No

  N/A

• Are eyewash and safety shower units unobstructed, clearly marked and operable? Activate the shower/eyewash to verify operation.

  Yes

  No

  N/A

• Visually inspect designated walkways. Are they free of holes, missing floor blocks or other items that could cause someone to trip?

  Yes

  No

  N/A

• Is overhead lighting in working condition?

  Yes

  No

  N/A

• Interview team members for knowledge of the daily safety circle topics.

  Yes

  No

  N/A

• Select several Production Centers. Can you locate the "Safe Work Instructions?"

  Yes

  No

  N/A

• Is it current and does it address the hazards and controls needed? List the PCs reviewed and the date the document was last revised.

  Yes

  No

  N/A

• Are packing horses and jigs in working condition?

  Yes

  No

  N/A

• Complete a visual inspection of the lockers and toolboxes. Are the lockers and toolboxes free from chemicals?

  Yes

  No

  N/A

Ergonomics

• Answer the following Ergonomics questions

Open Ergonomics

• Is the Team Member lifting with the legs and not the back?

  Yes

  No

  N/A

• If a hoist is available, is the team member using the hoist?

  Yes

  No

  N/A

• Are All hand tools, slings, and other items stored between waist and chest height?

  Yes

  No

  N/A

• Are adjustable height carts provided where needed?

  Yes

  No

  N/A

• Heavy objects are not being moved or lifted by hand- material handling equipment is being used instead?

  Yes

  No

  N/A

• "Cheater Bars" or pipes are not being used on the end of tools to provide more<br> leverage.

  Yes

  No

  N/A

• Are powered rollers, lifting devices, lift arms and other material handling equipment operating properly?

  Yes

  No

  N/A

• Are the proper tools being used for the job?

  Yes

  No

  N/A

Contractor Safety

• Answer the following Contractor Safety Questions

Open Contractor Safety

• Has a pre-job safety briefing been conducted?

  Yes

  No

  N/A

• If the job has lasted longer than 1 day, has an audit been performed?

  Yes

  No

  N/A

• Have documented pre-operational inspections been performed on contractor equipment?

  Yes

  No

  N/A

• Are the contractors in possession of their Green Cards?

  Yes

  No

  N/A

Transfer Rollers/Carts/Dollies , Jibs and Gantries

• Answer the following questions regarding transfer rollers/carts/dollies, jibs and gantries.

Open Transfer Rollers/Carts/Dollies, Jibs and Gantries

• Are capacities clearly marked and are they visible/readable on jibs and gantries?

  Yes

  No

  N/A

• Are these capacities being followed?

  Yes

  No

  N/A

• Are personnel walking, working, or standing clear of moving carts/dollies?

  Yes

  No

  N/A

• Is a spotter on a fork truck utilized to clear the path for the dolly transfer?

  Yes

  No

  N/A

• Do power pushers or fork trucks sound their horn when pushing carts to notify pedestrians (ie: when pushing dolly?)

  Yes

  No

  N/A

• Are safety latches provided on jibs and gantries?

  Yes

  No

  N/A

• Has a documented pre-op been completed for this shift when the jib/gantry is used?

  Yes

  No

  N/A

Racks

• Answer the following questions regarding racks

Open Racks

• Were all racks observed stacked properly and not leaning? (Fully seated)

  Yes

  No

  N/A

• Review rack-stacking areas next to pedestrian aisles and work areas. Do rack heights comply with stack heights as follows:<br> * 2 high in first row<br> * 3 high in second row<br> * 4 high in fourth row

  Yes

  No

  N/A

• Visually inspect a large sample of racks. Were all racks inspected free of damage?

  Yes

  No

  N/A

• Do personnel avoid walking between racks stacked more than 4 high?

  Yes

  No

  N/A

• Interview operators. Do they know not to climb racks?

  Yes

  No

  N/A

• Can they describe an alternative way to check rack tags, etc.?

  Yes

  No

  N/A

• Visually check a large sample of scrap tubs. Are the tubs free of trash such as cans, cardboard, etc.?

  Yes

  No

  N/A

Overhead Cranes and associated Jobs

• Answer the following questions related to Overhead Cranes and associated Jobs

Open Overhead Cranes and associated Jobs

• Observations confirm that lifting devices and loads are not being carried over personnel?

  Yes

  No

  N/A

• Crane horns are sounded to alert personnel when lifting devices and/or loads will be carried overhead?

  Yes

  No

  N/A

• Do operators stand a good distance (5 feet) away from crane lifting devices as they are being lowered and raised and when loading/unloading metal?

  Yes

  No

  N/A

• Observations confirm crane operator follows all hand signals.

  Yes

  No

  N/A

• Interview several crane operators. Do they understand the purpose of the limit switch?

  Yes

  No

  N/A

• Is it tested in an area free of personnel?

  Yes

  No

  N/A

• Observations confirm that limit switch is not being used as an operating control device.

  Yes

  No

  N/A

• Are cranes stopped from moving over pedestrian aisle ways five minutes before and after the three standard shifts?

  Yes

  No

  N/A

• Is the load to be lifted positioned properly?

  Yes

  No

  N/A

• Does the operator have the load under control? (No excessive swing)

  Yes

  No

  N/A

• Are slings visually inspected before use?

  Yes

  No

  N/A

• When pulling slings from a bar, are the slings positioned on opposite sides of the bar?

  Yes

  No

  N/A

• Is crane operator knowledgable of all rack stacking and transferring procedures?

  Yes

  No

  N/A

• Is a documented pre-op inspection available for the current shift and has it been completed properly? Identify the cranes reviewed.

  Yes

  No

  N/A

• Are lifting devices lowered to the floor when the operator is away from the remote or pendant controls?

  Yes

  No

  N/A

Cardboard Storage

• Answer the following questions related to cardboard storage

Open Cardboard Storage

• Are No Smoking signs posted wherever cardboard is stored?

  Yes

  No

  N/A

• If Hot work operations are performed in or around the cardboard storage area, are precautions identified on the permit?

  Yes

  No

  N/A

• Are cardboard stacks stacked no more than one high?

  Yes

  No

  N/A

Ovens and Furnaces

• Answer the following questions related to Ovens and Furnace

Open Ovens and Furnaces

• Are Team Members allowing the die oven door to completely open before entering the oven?

  Yes

  No

  N/A

• Select several ovens and furnaces. Are written start-up and shut-down procedures posted? List ovens and furnaces reviewed.

  Yes

  No

  N/A

• Do the procedures identify the need to close and open the manual gas valve?

  Yes

  No

  N/A

• Can you locate the manual gas valve?

  Yes

  No

  N/A

• Is it identified on the LTT map and is it marked?

  Yes

  No

  N/A

• Interview oven and furnace operators. Can they describe the start-up and shut-down procedures?

  Yes

  No

  N/A

• Are they aware of the need to close the manual gas valve when the furnace or oven is not operating?

  Yes

  No

  N/A

Caustic Area

• Answer the following questions related to the Caustic Area(s)

Open Caustic Area

• Is the eyewash station clear of obstacles?

  Yes

  No

  N/A

• When entering tanks, is all PPE being worn? Face shield, goggles, chemical apron, and rubber gloves?

  Yes

  No

  N/A

• Are operators knowledgeable of the clean-up procedure?

  Yes

  No

  N/A

• Is the area clearly posted with "No Smoking" signs and lines painted?

  Yes

  No

  N/A

• Are ladders in the area secured in designated locations?

  Yes

  No

  N/A

Presses

• Answer the following questions regarding the Extrusion Presses

Open Presses

• Interview operators. Are they aware of the potential for very serious injury when looking into the mouth of the Press?

  Yes

  No

  N/A

• Observations confirm operators are not looking in the mouth of the press during breakout.

  Yes

  No

  N/A

• Are warning signs posted not to look into platen?

  Yes

  No

  N/A

• Observe operators loading billets. Are they using tools provided for this purpose?

  Yes

  No

  N/A

• Interview operators. Are they aware of the risk associated with mists of hydraulic fluids?

  Yes

  No

  N/A

• Visually inspect hydraulic pump areas. Observations confirm that there is no evidence of running or spraying leaks.

  Yes

  No

  N/A

• Observations confirm that operators are not placing themselves in the line of fire (Press 5 Puller).

  Yes

  No

  N/A

• Are operators aware of the need to visually inspect the ram for metal buildup?

  Yes

  No

  N/A

Casting Operation

• Answer the following questions regarding the Casting Operation

Open Casting Operation

• Is the platform fall protection system being properly used while pulling logs?

  Yes

  No

  N/A

• Randomly interview operators. Do they know when to use the fall protection system?

  Yes

  No

  N/A

• Is the mechanical safety stop being used when the cast table is in the raised position?

  Yes

  No

  N/A

• Are drain molds free of trash and debris? Verify all are coated or oiled.

  Yes

  No

  N/A

• Are drain molds ready, warm, and in proper positions at the casting units?

  Yes

  No

  N/A

• Fall protection platform is in good working order? (Lids, chains, etc.)

  Yes

  No

  N/A

• Are operators wearing their full PPE while starting drops? First 20 inches.

  Yes

  No

  N/A

• Are team members face shields down when working around molten metal?

  Yes

  No

  N/A

• Observe SNIF box operations around skimming/cleaning & maintenance work to verify that all 4 safety pins are used any time the lid is in the full "up" position.

  Yes

  No

  N/A

• Is proper PPE being worn at all times when working around molten metal? Gloves, etc.

  Yes

  No

  N/A

• Observe team members operating the overhead crane, and verify the safety pin is being used when moving loads.

  Yes

  No

  N/A

• Is housekeeping in order at time of audit? List areas observed.

  Yes

  No

  N/A

• Check and verify emergency sand tubs are full and clutter free. List areas.

  Yes

  No

  N/A

• Is the height indicator in place and being used?

  Yes

  No

  N/A

• Are Emergency Stop off plugs in proper condition and in place located on the casting table?

  Yes

  No

  N/A

• Are cooling fans in proper condition and dust free?

  Yes

  No

  N/A

• Are cooling fan guards, cords, and tags in place and in proper condition?

  Yes

  No

  N/A

Melting Operations

• Answer the following questions regarding Melting Operations

Open MeltIng Operations

• Interview operators. Can they describe the procedure for preheatIng magnesium?

  Yes

  No

  N/A

• Inspect magnesium that has been preheated for adding to the trough. Is it free of moisture and debris?

  Yes

  No

  N/A

• Are people standing away from the trough after the addition of magnesium?

  Yes

  No

  N/A

• Inspect RSI, pig and other solid material. Is it free from debris, oxidation and moisture?

  Yes

  No

  N/A

• Is there a working flashlight at the casting units?

  Yes

  No

  N/A

• Is mg and prime preheated before being charged?

  Yes

  No

  N/A

• Are furnace personnel wearing a cast coat while transferring metal?

  Yes

  No

  N/A

• Are the cast coats secure and face shields being worn in the down position while transferring?

  Yes

  No

  N/A

• Inspect oxygen and propane storage locations. Are they all in order and not mixed?

  Yes

  No

  N/A

Homogenizing Furnaces

• Answer the following questions related to the homogenizing furnaces

Open Homogenizing Furnaces

• Do Ingot operators or Maintenance personnel stand to the side when raising or lowering the door?

  Yes

  No

  N/A

• When performing maintenance,is the door removed or chained and proper L/T/T procedure followed?

  Yes

  No

  N/A

Degassers

• Answer the following questions related to the degassers.

Open degassers

• Are the rotors preheated prior to submerging?

  Yes

  No

  N/A

• Interview the DC unit operators,did they inspect the selee bowl and rotors before use?

  Yes

  No

  N/A

• Are operators wearing cast coats and face shields while performing preparation tasks?

  Yes

  No

  N/A

• Are the proper gloves being worn while working around degassers?

  Yes

  No

  N/A

• Observe SNIF box operations around skimming/cleaning & maintenance work to verify that all 4 safety pins are used anytime the lid is in the full up position.

  Yes

  No

  N/A

• Visually inspect designed walkways. Are they free of holes, missing floor blocks or other items that could cause someone to trip?

  Yes

  No

  N/A

• Are furnace personnel wearing cast coats while transferring metal?

  Yes

  No

  N/A

• Were all employees observed wearing hearing protection properly?

  Yes

  No

  N/A

• Check and verify that Ingot's rosebuds are in proper working condition, regulators drained, hoses, flashback arresters in place, etc;

  Yes

  No

  N/A

• Inspect oxygen and propane storage locations to verify that all are in order and not mixed.

  Yes

  No

  N/A

Audit Complete

• Auditor Signature

  Sign