• Department

  • Area within department

  • Auditor

  • Audit Date and Time

Confined Space

  • Answer the following questions for each Confined Space

  • Open Confined Space
  • Is the confined space permit completed correctly?

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

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

  • Is the confined space center clean and organized?

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

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

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

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

  • Are all monitors present or accounted for?

  • Has the space been monitored for atmospheric hazards?

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

  • 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?

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

  • Does the probe contain an inline filter?

Electrical Safety

  • Answer the following questions for Electrical Safety

  • Open Electrical Safety
  • Are electricians performing per shift glove testing?

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

  • Has a safe work zone been established?

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

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

  • Are tools and PPE clean and dry?

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

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

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

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

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

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

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

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

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

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

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

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?

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

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

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

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

  • Do vehicle operators look while backing?

  • 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?

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

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

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

  • Is the vehicle's PM current?

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

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

  • Are designated walkways clear of obstructions such as racks?

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

  • Are the mirrors clean and in good condition?

  • Are they adjusted properly?

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

  • 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?

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

Lockout Tagout Verify

  • Answer the following questions regarding Lockout Tagout Verify

  • Open Lockout Tagout Verify
  • Are red and white danger tags legible?

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

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

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

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

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

  • Is the lockout procedure posted at the equipment?

  • Are all isolation points tagged or otherwise identified?

  • Did the Team Member properly isolate the equipment?

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

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

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

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

  • Is Lockout performed when Team Members enter Crane Envelope?

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

Machine Guarding

  • Answer the following questions related to Machine Guarding

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

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

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

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

  • Are the machine guards in good condition?

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

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

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

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

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

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

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

Fall Prevention/Protection

  • Answer the following questions regarding Fall Prevention/Protection

  • Open Fall Prevention/Protection
  • Has the roof work permit been properly completed?

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

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

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

  • 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)

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

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

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

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

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

  • Are employees using anchor points provided on cranes?

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

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

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

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

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

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

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)?

  • Are fire extinguisher inspections up to date?

  • Are all fire extinguishers observed un-obstructed?

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

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

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

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

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

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

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

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

  • Check several phones. Are they working?

  • In good condition?

  • Provided with emergency sticker?

  • Are blue phone signs posted?

  • Are evacuation maps posted throughout the work area?

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

  • Is the emergency lighting working? Test.

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

Housekeeping

  • Answer the following questions related to Housekeeping

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

  • Are tools and equipment stored properly?

  • Are trash cans NOT more than 75% full?

  • Are the Safety Circles clear of materials and equipment?

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

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

  • Are operators knowledgeable of clean up procedures?

  • Is appropriate equipment available and being used?

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

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

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

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

  • Is the tool crib organized?

Personal Protective Equipment (PPE)

  • Answer the following questions related to PPE

  • Open Personal Protective Equipment (PPE)
  • Were all employees observed wearing hearing protection properly?

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

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

  • 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.)

  • Are Hard Hats clean and free of damage?

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

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

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?

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

  • Are all safety signs clean and readable?

  • 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.

  • Is metal banding from logs disposed of properly?

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

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

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

  • Is overhead lighting in working condition?

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

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

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

  • Are packing horses and jigs in working condition?

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

Ergonomics

  • Answer the following Ergonomics questions

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

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

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

  • Are adjustable height carts provided where needed?

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

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

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

  • Are the proper tools being used for the job?

Contractor Safety

  • Answer the following Contractor Safety Questions

  • Open Contractor Safety
  • Has a pre-job safety briefing been conducted?

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

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

  • Are the contractors in possession of their Green Cards?

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?

  • Are these capacities being followed?

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

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

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

  • Are safety latches provided on jibs and gantries?

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

Racks

  • Answer the following questions regarding racks

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

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

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

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

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

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

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

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?

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

  • 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?

  • Observations confirm crane operator follows all hand signals.

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

  • Is it tested in an area free of personnel?

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

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

  • Is the load to be lifted positioned properly?

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

  • Are slings visually inspected before use?

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

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

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

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

Cardboard Storage

  • Answer the following questions related to cardboard storage

  • Open Cardboard Storage
  • Are No Smoking signs posted wherever cardboard is stored?

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

  • Are cardboard stacks stacked no more than one high?

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?

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

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

  • Can you locate the manual gas valve?

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

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

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

Caustic Area

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

  • Open Caustic Area
  • Is the eyewash station clear of obstacles?

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

  • Are operators knowledgeable of the clean-up procedure?

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

  • Are ladders in the area secured in designated locations?

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?

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

  • Are warning signs posted not to look into platen?

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

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

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

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

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

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?

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

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

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

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

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

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

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

  • 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.

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

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

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

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

  • Is the height indicator in place and being used?

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

  • Are cooling fans in proper condition and dust free?

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

Melting Operations

  • Answer the following questions regarding Melting Operations

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

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

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

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

  • Is there a working flashlight at the casting units?

  • Is mg and prime preheated before being charged?

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

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

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

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?

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

Degassers

  • Answer the following questions related to the degassers.

  • Open degassers
  • Are the rotors preheated prior to submerging?

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

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

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

  • 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.

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

  • Are furnace personnel wearing cast coats while transferring metal?

  • Were all employees observed wearing hearing protection properly?

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

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

Audit Complete

  • Auditor Signature

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