Information

  • Audit Title

  • Document No.

  • Client / Site

  • Conducted on

  • Prepared by

  • Location
  • Personnel

3.0 Scope

  • Review the scope of documents used to implement this FPE. Do they require the application of the requirements of this FPE to all machinery and plant operating within the Group Company?

4.0 Accountability

  • Is there a process in place for formally appointing a person or persons other than CEO to be accountable to implement and maintain each requirement<br><br>Document:<br>• As a minimum the accountability section of the FPE has been completed showing the appointed person

  • Has a person or persons other than the CEO been assigned accountability for implementing and maintaining each requirement of this FPE?<br><br>Document:<br>• As a minimum there must be a filed copy of the FPE with appointed persons column completed

4.1 Hazard identification risk assessment and control

4.1.1

  • Have appropriate standards for guarding and safety devices for moving machinery been established? <br><br>Documents:<br>• Machine Guarding and safety device standard, e.g. ISO, Local regulation/standard.<br>• Machine Guarding Assessment criteria or inspection checklist.

  • Has a survey been conducted to identify if appropriate guarding and or safety devices has been installed on moving machinery?

  • Does the survey meet the record the minimum requirements of this FPE?<br><br>As a minimum the survey will record the following:<br>• Location of all machinery/equipment both fixed and portable;<br>• The type/s of machine guard or safety device fitted;<br>• Confirm if the machine is fitted with an emergency stop or shut off device;<br>• If follow up action is required to rectify any defects or deficiencies; and<br>• The date the survey was performed.<br><br>Documents:<br>• Machine Guarding Survey.<br>• Improvement Action Plan.<br>

4.1.2

  • Have the required procedures been established?

  • What authority is required to remove machine guards – is it contained to isolation and lockout requirements? <br>

  • What range of situations occur which require machines to be tested with the machine guard removed and/ or safety device disabled?

4.1.3

  • Is there a process in place to ensure the documents and records relating to the surveys are retained until the machine is removed from service or decommissioned?

4.2 Selection, Training, Competency and Authorisation

4.2.1

  • Is there instruction provided to personnel who conduct machine guarding surveys?

  • Does the training material cover all aspects of machine guarding?

  • Does it cover how to determine adequacy of machine guards/devices?

  • Does it cover the types of Guards including design requirements?

  • Does it cover the types of safety devices that can be used in conjunction with machine guarding?

  • Does it cover Information which must be recorded with the survey and corrective actions?<br>

4.2.2

  • Is an overview of the company’s requirements for machine guarding included as part of the general induction for all personnel?

4.3 Communication and awareness

4.3.1

  • Is machine guarding awareness information provided to personnel?

  • Is the awareness material relevant to the range of guarding issues at the facility/ plant?<br>

  • How frequent is machine guarding covered as a topic during safety forums e.g. Quarterly, six monthly?

  • Is information on incidents, hazards and inspections related to machine guarding issues included?

  • Interview personnel to confirm they understand the safety requirements related to machine guarding.

4.3.2

  • Are there any machines which use interlocks instead of guarding?

  • Is signage in place?

  • Are signs written in language which is understood by employees?

4.4 Design, Purchase, Fabrication, Installation and Commissioning

4.4.1

  • Have design standards for machine guarding and safety devices based on national or international engineering standards been established?<br><br>The design standards must consider the following:<br>· Guards can be easily removed and replaced (lifting points, handles, access covers);<br>· Guards can only be removed with the aid of a tool or used in conjunction with an interlock;<br>· Materials used are of good quality and durable to prevent access and/or the ejection of material or objects;<br>· Positioning of the guard provides adequate clearance between the hazard and the reach point of body parts being protected; and<br>* Machine guards must be clearly distinguishable from other structures i.e. through colour coding or signage.

  • Does the design specification require that Machine guards do not create ergonomic hazards, when being handled or removed?

  • Does the design specification require that guards can only be removed with the aid of a tool or be connected to an interlock?

  • Does the design standard specify the durability of the guards taking into account their duty?

  • The design considers distances from hazardous areas on machines?

  • Does the design specification require machine guards to be clearly distinguishable through colour coding or signage?<br>

4.4.2

  • Is there a pre-commissioning process implemented which requires that new machinery meets the machine guarding design standard?<br>

  • Is a Checklist used to determine if the machine guard is adequate?

  • Do engineering/ projects including machine guarding requirements in the procurement of new equipment?

  • Hire equipment must conform to guarding standards

  • Are inspections/ commissioning checks performed on contractors machinery and guarding?

4.4.3

  • Is there a process in place for modifications to machine guarding to be improved e.g. change management process?

  • Does the process require a competent person to approve the change i.e. some who is knowledgeable about machine guarding?

  • Are engineering drawings updated when a change is made

4.5 Work method and condition control

4.5.1

  • Is the prohibition for the removal of machine guards or disabling of safety devices unless the machine is isolated and locked out clearly stated by the group company?<br><br>Documents:<br>· Company rules stating safety requirements for working near moving machinery. <br>· Induction handbook.<br>

4.5.2

  • Are the requirements of this section of this FPE clearly stated by the group company in the form of site rules or equivalent?

  • Are these rules reinforced at the machine location by way of warning signage e.g. mandatory blue circles and pictograms plus verbal warning in local language and English?

4.6 Maintenance

4.6.1

  • Has a maintenance program been established in accordance with the element requirements?<br><br>Documents:<br>· Maintenance Schedules.<br>· Manufacturers Specifications.<br>· Maintenance / Repair Records.

4.7 Emergency control

4.7.1

  • Is there a Standardised approach to identifying emergency switches and devices?

4.7.2

  • Is training provided to first aid personnel to specifically deal with trauma as a result of contact with moving machine parts?

  • Is First Aid response information on , fractures, major bleeds, amputations provided?

4.8 Monitoring, inspection and audits

4.8.1

  • Is there a monthly machine guard and safety device inspection program in place?

  • Does the monthly inspection program meet the requirements of this section of the FPE?<br><br>The inspection program will comprise of the following features:<br>· Use of a formal checklist<br>· Inspections are performed by a competent person<br>· Requirements for inspections to be undertaken in accordance with manufacturer specifications and operational experience<br>· The recording of all inspections conducted<br><br>Note: The inspection program can be either separate or form part of the routine planned inspection program refer OHS Pyramid Element – Planned Inspections.<br><br>Documents:<br>· Specific Inspection Checklists or<br>· monthly workplace inspections records (12 month history of records).<br>· Hazard / Defect Reports.<br>· Corrective actions from inspections.

4.8.2

  • Is there an annual auditing program in place, which verifies the quality and effectiveness of the group company’s response to the requirements of this FPE?

  • Are the audits performed in accordance with the audit schedules?

4.9 Reporting, assessment and corrective actions

4.9.1

  • Is there a process in place to report, assesses and correct hazards or defects associated with machine guarding and or safety devices?

  • Are the requirements to stand down machines with missing or damaged guards clear?

  • Are the actions taken to correct the defect recorded?

  • Are there clear requirements which must be met before a machine can be restarted having been shut down for a missing or damaged guard?

Conclusion and auditor's comments

  • Date of audit completed

  • Signature of auditor

  • Date of auditor's signature

  • Signature of auditee

  • Date of auditee's signature

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