JNS Plant Safety Audit

• Site conducted

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  • AZ Janus
  • IN Janus
  • Temple Janus
  • TX Janus
  • GA ASTA
  • TX ATSA
  • BETCO
  • Other

• What site are you auditing?

• Conducted on

  Date

• Prepared by

• Additional people on audit from plant and audit team:

• Location
  Address

• Access OSHA logs for the last 5 years

  Compliant

  Non-Compliant

  N/A

• Show completed required training for the past 12 months

  Compliant

  Non-Compliant

  N/A

• Show certified forklift operators and training docs

  Compliant

  Non-Compliant

  N/A

• Show certified crane operators and training docs

  Compliant

  Non-Compliant

  N/A

• Show completed training for authorized LOTO employees

  Compliant

  Non-Compliant

  N/A

• Show completed general training for affected LOTO employees

  Compliant

  Non-Compliant

  N/A

• Show Hot Work training completion

  Compliant

  Non-Compliant

  N/A

• Have authorized LOTO employees who perform LOTO been trained and signed off?

  Yes

  No

  N/A

• Have all other affected employees been trained and signed off?

  Yes

  No

  N/A

• Are LOTO procedures or QR codes posted on all equipment?

  Yes

  No

  N/A

• Which equipment is missing LOTO procedures?

  Yes

  No

  N/A

• Is there a sufficient supply of lockout devices (padlocks, hasps, valve lockouts, etc.)?

  Yes

  No

  N/A

• Are lockout locks standardized by color, size or shape?

  Yes

  No

  N/A

• LOTO locks must be standardized by either color, size, or shape.

• How are the locks standardized?

  Color

  Shape

  Size

• Are energy isolation points clearly labeled and identified on all equipment?

  Yes

  No

  N/A

• Is verification of isolation performed before starting maintenance work?

  Yes

  No

  N/A

• Are all affected workers notified before the start of maintenance or servicing activities?

  Yes

  No

  N/A

• Are regular audits of the LOTO program conducted (at least annually)?

  Yes

  No

  N/A

• Are audit findings documented, and corrective actions taken for any deficiencies?

  Yes

  No

  N/A

Housekeeping

• When conducting a safety audit with a focus on housekeeping, it's essential to ask questions that help identify potential hazards, ensure compliance with safety standards, and maintain a clean and organized environment. Here are some housekeeping-related questions you could consider:

• What area are you auditing?

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  • Doors
  • Axles
  • Fab
  • Shipping
  • Clipping
  • Guides
  • Other
  • Maintenance
  • Entire Plant

• What is the area you are auditing?

• Is there clutter and other debris on the floor?

  Yes

  No

  N/A

• What items are on the floor that should not be?

• Around the work area are there items that should not be in the area?

  Yes

  No

  N/A

• What items should not be in the area?

• Are there any trash bins that are full and need to be taken out?

  Yes

  No

  N/A

• Are all tools, equipment, and supplies stored properly to prevent tripping or injury?

  Yes

  No

  N/A

• Is all equipment and materials stored in designated areas to avoid accidents?

  Yes

  No

  N/A

• Are shelves and storage racks properly labeled and organized to prevent unsafe stacking or overloading?

  Yes

  No

  N/A

• Are flammable or hazardous materials stored correctly according to safety guidelines?

  Yes

  No

  N/A

• Are walkways and exits unobstructed, with no stored items blocking access?

  Yes

  No

  N/A

• How do you rate the housekeeping in this area? 10 is perfect and 1 is very bad

• Are all pedestrian walkways clear of obstruction?

  Yes

  No

  N/A

• Note any other issues good and bad:

PPE

• When conducting a safety audit with a focus on Personal Protective Equipment (PPE), it's important to ensure that the proper equipment is being used, maintained, and readily available for employees to minimize workplace hazards. Here are some key questions you can ask related to PPE during a safety audit:

• What area are you auditing?

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  • Doors
  • Axles
  • Fab
  • Shipping
  • Clipping
  • Guides
  • Other
  • Maintenance
  • Entire Plant

• What area are you auditing?

• Is the necessary PPE readily available to all employees in the required areas?

  Yes

  No

  N/A

• Are employees able to easily access the proper PPE without delays or difficulty?

  Yes

  No

  N/A

• Is the PPE selected appropriate for the specific hazards present in the workplace?

  Yes

  No

  N/A

• Are employees aware of the potential risks of not using PPE?

  Yes

  No

  N/A

• Are areas requiring PPE clearly marked with appropriate signage?

  Yes

  No

  N/A

• How many people are working in the area?

• How many people are wearing safety glasses correctly?

• How many are wearing hearing protection correctly?

• How many are wearing cut resistant sleeves correctly? (count people who are not required in this number)

• How many are wearing cut resistant gloves correctly? (count people who are not required in this number)

• Overall how would you rate the PPE usage in this area? (10 is perfect and 1 is very bad)

• Any additional comments:

Electrical

• undefined

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  • Doors
  • Axles
  • Fab
  • Shipping
  • Clipping
  • Guides
  • Other
  • Maintenance
  • Entire Plant

• Conducting an electrical safety audit in a manufacturing plant is essential to identify and mitigate electrical hazards that could lead to accidents, fires, or other safety concerns. An electrical safety audit should examine the facility’s systems, equipment, maintenance, and employee practices. Below are key questions you can use for an electrical safety audit in a manufacturing plant:

• What area are you auditing?

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  • Doors
  • Axles
  • Fab
  • Shipping
  • Clipping
  • Guides
  • Other
  • Maintenance
  • Entire Plant

• What area are you auditing?

• Are electrical panels and equipment clearly labeled to identify their function and any hazards?

  Yes

  No

  N/A

• Are all electrical panels and circuit breakers easily accessible and not obstructed by materials or equipment?

  Yes

  No

  N/A

• Identify issues:

• Is electrical wiring properly routed, supported, and protected from damage (e.g., no exposed or frayed wiring)?

  Yes

  No

  N/A

• Are extension cords and temporary wiring being used properly and only for short-term needs, not as permanent solutions?

  Yes

  No

  N/A

• Are electrical devices (plugs, receptacles) in good working condition, with no exposed wiring, missing prongs, or faulty connections?

  Yes

  No

  N/A

• Are electrical systems and equipment protected from exposure to moisture, dust, or other environmental hazards that could cause short circuits or other problems?

  Yes

  No

  N/A

• Are proper barriers or enclosures in place to prevent accidental contact with exposed live parts?

  Yes

  No

  N/A

• Are electrical panels, junction boxes, and switchgear labeled with warning signs or labels to identify electrical hazards (e.g., “High Voltage” or “Shock Hazard”)?

  Yes

  No

  N/A

Chemicals/SDS/Hazardous Waste

• When conducting an audit for chemicals, Safety Data Sheets (SDS), and hazardous waste in a manufacturing plant, the goal is to ensure that hazardous materials are managed in a safe, compliant, and environmentally responsible manner. The audit should assess how chemicals are stored, handled, and disposed of, as well as ensure that employees are properly trained on their safe use. Below is a list of questions that can guide your audit in these areas:

• What area are you auditing?

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  • Doors
  • Axles
  • Fab
  • Shipping
  • Clipping
  • Guides
  • Other
  • Maintenance
  • Entire Plant

• What area are you auditing?

• Are all chemicals properly labeled with their identity and hazard warnings (e.g., flammable, corrosive, toxic)?

  Yes

  No

  N/A

• Are chemicals stored in designated areas according to their type and compatibility (e.g., acids separate from bases, flammables away from ignition sources)?

  Yes

  No

  N/A

• Are storage areas adequately ventilated to prevent the buildup of hazardous fumes or gases?

  Yes

  No

  N/A

• Are chemicals stored in appropriate containers (e.g., unbroken seals, corrosion-resistant materials) that prevent leaks or spills?

  Yes

  No

  N/A

• Is the chemical storage area equipped with secondary containment (e.g., spill pallets, trays) to prevent leaks from spreading?

  Yes

  No

  N/A

• Are flammable chemicals stored away from heat sources or open flames, and are appropriate fire prevention measures in place?

  Yes

  No

  N/A

• Are emergency response procedures in place for chemical spills, and do they include specific instructions based on the chemicals involved?

  Yes

  No

  N/A

• Are emergency eyewash stations, safety showers, or other first-aid equipment accessible near areas where chemicals are used or stored?

  Yes

  No

  N/A

• Are spill kits and clean-up materials readily available in areas where chemicals are used or stored?

  Yes

  No

  N/A

• Are employees trained in spill response, including how to contain, clean, and report spills promptly?

  Yes

  No

  N/A

• Are emergency contact numbers (e.g., local emergency responders, poison control) prominently displayed near chemical storage areas?

  Yes

  No

  N/A

• Is appropriate PPE (e.g., gloves, goggles, face shields, respirators) available and worn by employees handling chemicals?

  Yes

  No

  N/A

SDS

• Are current and complete SDS available for all chemicals used or stored on-site?

  Yes

  No

  N/A

• Are SDS easily accessible to all employees who may be exposed to chemicals (e.g., in a centralized location, digital access)?

  Yes

  No

  N/A

• Do SDS include proper hazard identification, including physical, health, and environmental hazards, as well as first-aid measures?

  Yes

  No

  N/A

• Are employees trained on how to read and understand SDS, and how to locate them in an emergency?

  Yes

  No

  N/A

Hazardous Waste

• Does this plant have hazardous waste?

  Yes

  No

  N/A

• Are hazardous wastes segregated according to type (e.g., solvents, oils, batteries) to prevent reactions or contamination?

  Yes

  No

  N/A

• Are hazardous waste containers clearly labeled with the contents, hazard warnings, and accumulation start dates?

  Yes

  No

  N/A

• are waste containers in good condition and regularly inspected for leaks or damage?

  Yes

  No

  N/A

• Are hazardous waste containers properly sealed when not in use to prevent spills or leaks?

  Yes

  No

  N/A

• Are waste containers stored in a secure, designated area with appropriate containment systems (e.g., spill pallets)?

  Yes

  No

  N/A

• Are hazardous wastes disposed of by an authorized, licensed waste disposal company in compliance with regulations?

  Yes

  No

  N/A

• Is there a written hazardous waste management plan, and is it reviewed regularly for compliance with local, state, and federal regulations?

  Yes

  No

  N/A

• Are employees trained in proper hazardous waste handling and disposal procedures, including emergency response?

  Yes

  No

  N/A

• Are records kept for the collection, transportation, and disposal of hazardous waste, and are these records up-to-date?

  Yes

  No

  N/A

Machine Safety

• When conducting a machine safety audit in a manufacturing plant, the goal is to identify potential hazards associated with the machinery and ensure that proper safety protocols are in place to protect workers. The audit should cover machine design, maintenance, safeguarding, and employee practices. Below are key questions to guide your machine safety audit:

• What area are you auditing?

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  • Doors
  • Axles
  • Fab
  • Shipping
  • Clipping
  • Guides
  • Other
  • Maintenance
  • Entire Plant

• What area are you auditing?

• Are machines equipped with appropriate safeguards to protect workers from moving parts (e.g., physical barriers, safety interlocks)?

  Yes

  No

  N/A

• Are all machine guards in place and functioning correctly (e.g., no missing or damaged guards)?

  Yes

  No

  N/A

• Are machine guards designed to prevent access to hazardous areas while still allowing workers to perform their tasks safely?

  Yes

  No

  N/A

• Are rotating parts, belts, pulleys, and gears properly guarded to prevent accidental contact?

  Yes

  No

  N/A

• Are machine guard openings designed to prevent any part of a worker's body from entering the danger zone (e.g., no gaps or holes in the guards)?

  Yes

  No

  N/A

• Do machine controls allow workers to operate the machinery from a safe distance or position?

  Yes

  No

  N/A

• Are machines equipped with emergency stop buttons that are easily accessible and clearly labeled?

  Yes

  No

  N/A

• Are safety devices such as light curtains, pressure-sensitive mats, or laser scanners in place for machines that require additional safety measures?

  Yes

  No

  N/A

• Is there a system in place for reporting and addressing unsafe machines or faulty equipment promptly?

  Yes

  No

  N/A

• Are machines and equipment regularly inspected for safety and operational integrity (e.g., visual inspections, functional tests)?

  Yes

  No

  N/A

• Are maintenance schedules documented and adhered to for routine checks and repairs?

  Yes

  No

  N/A

• Are worn or damaged parts replaced in a timely manner to maintain machine safety and proper function?

  Yes

  No

  N/A

• Are there preventive maintenance programs to avoid unexpected breakdowns that could lead to unsafe conditions?

  Yes

  No

  N/A

• Are operators trained on safe machine operation, including hazard recognition, proper use, and emergency stop procedures?

  Yes

  No

  N/A

• Do operators know how to safely start, stop, and adjust machines, and are they familiar with all safety features of the machines they operate?

  Yes

  No

  N/A

• Are operators trained on the potential hazards associated with the specific machines they use (e.g., pinch points, electrical hazards, moving parts)?

  Yes

  No

  N/A

• Are electrical connections for machines properly installed and maintained (e.g., no exposed wires, no frayed cables)?

  Yes

  No

  N/A

Emergency Stops

• Are emergency stop buttons clearly marked, easily accessible, and functional on all machines?

  Yes

  No

  N/A

• Are emergency stop systems tested regularly to ensure they work properly in case of an emergency?

  Yes

  No

  N/A

• Are employees trained in how to activate emergency stops or shut down machines safely in case of a malfunction or emergency?

  Yes

  No

  N/A

Signage

• Are safety signs and labels present on or near machines to identify hazards (e.g., moving parts, pinch points, electrical hazards)?

  Yes

  No

  N/A

• Are safety labels clear, legible, and placed in visible locations on machinery and equipment?

  Yes

  No

  N/A

• Do the safety signs include specific warnings (e.g., “Keep Hands Away,” “High Voltage,” “Wear PPE”) based on the hazards present?

  Yes

  No

  N/A

Noise

• Are noise levels measured around machinery to ensure they are within permissible limits (e.g., OSHA noise exposure limits)?

  Yes

  No

  N/A

• Note some dBs around equimpment including where you are and what equipment you are near:

• Is there a 1st responders team?

  Yes

  No

  N/A

• A 1st responder team is important and should be established.

• When were they last certified/trained? (required biannually)

  Yes

  No

  N/A

• Is there at least 1 AED in the plant?

  Yes

  No

  N/A

• Have there been 1st responders trained in how to use it?

  Yes

  No

  N/A

• Is the 1st responder team posted for people to see?

  Yes

  No

  N/A

• Is there a dedicated 1st aid room?

  Yes

  No

  N/A

• How does the room look from housekeeping standard?

  Good

  Fair

  Poor

  N/A

• Is there a 1st aid cabinet in the room?

  Yes

  No

  N/A

• Is it fully stocked?

  Yes

  No

  N/A

• Are there adequate 1st aid cabinets in the plant?

  Yes

  No

  N/A

• Are employees trained in fire safety and emergency response procedures?

  Yes

  No

  N/A

• Is there an operational fire detection and alarm system in place (e.g., smoke detectors, heat detectors)?

  Yes

  No

  N/A

• Are detectors and alarms tested regularly, and is there a maintenance schedule? (verify documentation)

  Yes

  No

  N/A

• Is the fire alarm system linked to an external emergency service (e.g., local fire department)?

  Yes

  No

  N/A

• Yes

  No

  N/A

Fire Extinguishers

• Are fire extinguishers available and accessible throughout the facility?

  Yes

  No

  N/A

• Are fire extinguishers of the correct type for the hazards present (e.g., Class A, B, C, D, K)?

  Yes

  No

  N/A

• Are fire extinguishers inspected monthly, and are inspection records kept?

  Yes

  No

  N/A

• Are fire extinguishers mounted in clear, unobstructed locations?

  Yes

  No

  N/A

• Are tags on the fire extinguishers up to date and signed/dated?

  Yes

  No

  N/A

• Are employees trained on the proper use of fire extinguishers (PASS method)?

  Yes

  No

  N/A

• Is there a fixed fire suppression system (e.g., sprinklers, chemical suppression) in high-risk areas?

  Yes

  No

  N/A

• Are all fire extinguishers unobstructed?

  Yes

  No

  N/A

• Are fire extinguisher locations clearly marked?

  Yes

  No

  N/A

Emergency exits and evacuation routes

• Are emergency exits clearly marked with illuminated exit signs?

  Yes

  No

  N/A

• Are emergency exit routes free of obstructions and properly maintained?

  Yes

  No

  N/A

• Are exit doors easy to open from the inside without the use of a key or special knowledge?

  Yes

  No

  N/A

• Are evacuation plans clearly posted in common areas?

  Yes

  No

  N/A

• Do employees know the nearest exit routes and assembly areas?

  Yes

  No

  N/A

Fire equipment and maintenance

• Are fire safety systems inspected annually by a licensed professional? (verify documentation)

  Yes

  No

  N/A

Hot Work

• Are hot work permits required for activities like welding, cutting, or grinding? (Outside of designated hot work zones)

  Yes

  No

  N/A

• Are designated hot work zones clearly defined with signage?

  Yes

  No

  N/A

• Are designated hot work zones free of combustibles and flammables?

  Yes

  No

  N/A

• Are fire watch procedures in place when hot work is being conducted?

  Yes

  No

  N/A

• Are combustible materials removed or covered during hot work operations?

  Yes

  No

  N/A

• Is there an adequate supply of fire extinguishers in areas where hot work is performed?

  Yes

  No

  N/A

• Have people authorized to do hot work outside hot work zones been trained and signed off on training?

  Yes

  No

  N/A

• Have people working in hot work designated zones been trained properly and signed off on training?

  Yes

  No

  N/A

• Pull some random hot work permits and audit completions. Were they all fully completed?

  Yes

  No

  N/A

Culture

• Is safety viewed as a priority by management?

  Yes

  Somewhat

  No

• Do supervisors and managers actively model safe work behaviors?

  Yes

  No

  N/A

• Are safety meetings and discussions held regularly, and is there active participation from all levels?

  Yes

  No

  N/A

• How are safety meeting held on the regular basis?

Employee Engagement

• Are employees encouraged to report hazards, near misses, or unsafe behaviors without fear of retaliation?

  Yes

  No

  N/A

• Are employees actively involved in the development and implementation of safety procedures?

  Yes

  No

  N/A

• Are there mechanisms for employees to provide feedback on safety issues (e.g., safety committees, suggestion boxes)?

  Yes

  No

  N/A

• Are employees recognized or rewarded for demonstrating safe behaviors?

  Yes

  No

  N/A

• Is there accountability for employees who break known safety rules?

  Yes

  No

  N/A

Safe Work Practices

• Are safe work procedures documented and available for all tasks?

  Yes

  No

  N/A

• Are workers trained on and expected to follow safe work practices?

  Yes

  No

  N/A

• Are employees using appropriate personal protective equipment (PPE) as required for their tasks?

  Yes

  No

  N/A

• Are tools and equipment maintained in safe operating condition, and are employees trained to use them safely?

  Yes

  No

  N/A

• Are safe lifting techniques and ergonomic practices promoted for material handling tasks?

  Yes

  No

  N/A
Observe workers

• What area are you observing? (You may repeat this section in multiple area)

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  • Doors
  • Axles
  • Fab
  • Shipping
  • Clipping
  • Guides
  • Other
  • Maintenance
  • Entire Plant

• Are employees consistently following safety rules, including wearing the required PPE and using equipment correctly?

  Yes

  No

  N/A

• Are there any observable unsafe behaviors (e.g., bypassing safety devices, improper lifting, horseplay)?

  Yes

  No

  N/A

• Are employees observed working alone in hazardous areas without proper safeguards or communication protocols?

  Yes

  No

  N/A

• Are employees using tools or equipment that are not in proper working condition or have not been inspected?

  Yes

  No

  N/A

• Are employees using equipment in a manner that deviates from standard operating procedures (SOPs)?

  Yes

  No

  N/A

• Are employees familiar with the hazards in their work area and the necessary precautions?

  Yes

  No

  N/A

• Have you observed any unsafe acts?

  Yes

  No

  N/A

• Explain

• Have you observed good/safe acts worth sharing?

  Yes

  No

  N/A

• Describe event:

Supervisors and management

• Are supervisors and team leads consistently enforcing safety rules and providing guidance on safe work practices?

  Yes

  No

  N/A

• Are supervisors and team leads consistently "walking the walk" in safety? (always wearing all PPE, etc.)

  Yes

  No

  N/A

• Are supervisors conducting regular safety observations to identify unsafe behaviors and provide coaching when necessary?

  Yes

  No

  N/A

• Are safety audits or walk-arounds regularly performed by management and supervisors?

  Yes

  No

  N/A

• Are corrective actions taken when unsafe behaviors or conditions are identified during safety audits or observations?

  Yes

  No

  N/A

• Are safety meetings led by supervisors or employees, fostering active engagement?

  Yes

  No

  N/A

Reporting and Addressing Unsafe Behaviors

• Are employees encouraged and empowered to intervene when they observe unsafe behavior by a coworker?

  Yes

  No

  N/A

• Is there a formal process for reporting unsafe behaviors, near misses, and unsafe conditions?

  Yes

  No

  N/A

• Are reports of unsafe behaviors followed up with corrective actions or investigations?

  Yes

  No

  N/A

• Are employees aware of the reporting procedures and have they been trained on how to report safety concerns?

  Yes

  No

  N/A

• Are incidents, accidents, and near misses investigated to identify root causes and corrective actions?

  Yes

  No

  N/A

• Are findings from incident investigations shared with employees to prevent recurrence?

  Yes

  No

  N/A

• Is there a process for tracking corrective actions and ensuring they are implemented?

  Yes

  No

  N/A

• Do workers feel that their concerns about safety are taken seriously and addressed promptly?

  Yes

  No

  N/A

• Are Vector QR codes posted clearly throughout the plant?

  Yes

  No

  N/A

Supervisor interview (2-3 interviews)

• How do you communicate the importance of safety to your team?

• How often do you discuss safety during meetings?

• How often do you have one-on-one discussions about safety with your people?

• Can you give an example of how management or leadership has supported or encouraged safe work behaviors?

• How do you ensure that safety is prioritized alongside productivity and efficiency goals?

• Do you feel that safety is part of the overall company culture? Why or why not?

• What is something you are willing to do to help improve the safety culture?

Hourly Employee Interview (3-5 interviews, include 1 maintenance)

• How do you feel about the importance of safety in your day-to-day tasks?

• Can you describe how supervisors or upper management promote safety in the workplace?

• Are safety concerns or feedback from employees taken seriously by your supervisors?

  Yes

  No

  N/A

• How do you feel about the overall safety culture here—do you feel it’s truly a priority?

  Yes

  No

  N/A

• How do you think your co-workers feel about safety on their day-to-day tasks?

  Yes

  No

  N/A

• Do you know your safety coordinator?

  Yes

  No

  N/A

• Do you think there is something that supervisor, management, safety coordinator can do better to promote safety?

• How do you rate the importance of safety personally? (1 Poor, 10 Extremely Important)

• How do you rate the way your co-workers thinks about safety? (1 Poor, 10 Extremely Important)

• How do you rate the way your supervisor thinks about safety? (1 Poor, 10 Extremely Important)

• How do you rate the way the safety coordinator thinks about safety? (1 Poor, 10 Extremely Important)

• How do you rate the way upper management thinks about safety? (1 Poor, 10 Extremely Important)

• How do you rate the way Janus as a whole thinks about safety? (1 Poor, 10 Extremely Important)

• Additional Comments?

Production Manager Interview

• How do you rate the way supervisors thinks about safety? (1 Poor, 10 Extremely Important)

• How do you rate the way hourly employees thinks about safety? (1 Poor, 10 Extremely Important)

• How do you rate the way your safety coordinator thinks about safety? (1 Poor, 10 Extremely Important)

• How do you rate the way Janus as a whole (corporate) thinks about safety? (1 Poor, 10 Extremely Important)

• How do you rate the way you think about safety? (1 Poor, 10 Extremely Important)

• Do communicate the importance of safety to your supervisor teams? How so?

  Yes

  Somewhat

  No

• Explain

• Explain

• Explain

• What are some things for safety that you may need assistance from corporate to get completed?

• What is your vision for safety at your plant?

• Is there anything you would like to see out of your safety coordinator that you are not currently?

• Additional comments?