Oswego Works GEMBA Walk

• Document No.

• Audit Title

• Client / Site

• Conducted on

  Date

• Prepared by

• Location
  Address

• Personnel

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Section A: Machinery & Equipment

Section A1 - Cleanliness

• There are no piles of rags and oil absorbent materials around the base of leaking machinery.

  Yes

  No

  N/A

• There are no excessive leaking fluids: water, oil, solvents, etc., on or near machinery and equipment.

  Yes

  No

  N/A

• Spill trays are not full of leaking water, oil, solvents, etc.

  Yes

  No

  N/A

• There is no trash, debris, and unnecessary materials on or near the machinery or equipment.

  Yes

  No

  N/A

• There are no large amounts of process materials (scrap foil, UBC, dross, fluxing salts, dust, etc.) spilled around the process equipment.

  Yes

  No

  N/A

• There are no excessive and unnecessary tools and materials hanging on, leaning against or around machinery and equipment.<br>

  Yes

  No

  N/A

Section A2 - Machine Guarding

• Point of operation guarding that is hinged, is secured shut and requires a tool to open.

  Yes

  No

  N/A

• Machine shop equipment is guarded, i.e. lathes without chuck guards.

  Yes

  No

  N/A

• Guarding is in place while the machine is running and secured in place.

  Yes

  No

  N/A

• Grinders with correct tool rest and tongue guard adjustments

  Yes

  No

  N/A

• Machine shop tools are anchored to the floor.

  Yes

  No

  N/A

Section A3 - Electrical Equipment

• There are no open electrical boxes, nor any unprotected energized parts that non-qualified employees can be exposed to. This would include missing junction box covers, breaker panel covers, open knockout plug holes, etc.

  Yes

  No

  N/A

• There is restricted access to general employee to areas where unprotected energized parts are located, i.e. motor control rooms with open buses.

  Yes

  No

  N/A

• Electrical disconnect equipment is not obstructed and free access.

  Yes

  No

  N/A

• Electrical equipment has 36 inches of clear working space in front of it.

  Yes

  No

  N/A

• There are no flammable or combustible materials stored within 36 inches of transformers and electrical equipment that may spark.

  Yes

  No

  N/A

• There is no water on the floor in electrical equipment areas.

  Yes

  No

  N/A

• There are labeled emergency disconnects.

  Yes

  No

  N/A

• Note: motor control rooms and other electrical equipment rooms are not being utilized as areas for general storage, unless flammable and combustible materials can be significantly isolated. Also, storage in these areas increases the likelihood that non-qualified personnel will be in these high hazard areas.

  Yes

  No

  N/A

Section A4 - Material Handling Equipment (Fork trucks, Cranes, Conveyors, etc.)

• There are no modifications to any lifting device without written approval from the original equipment manufacturer.

  Yes

  No

  N/A

• Vehicles have fully functional braking systems, lights, horns, other warning devices, etc.

  Yes

  No

  N/A

• Vehicles in safe conditions, i.e.no bad fluid leaks, no damaged load bearing parts, no damaged cables, no fuel leaks, etc.

  Yes

  No

  N/A

• There are no damaged hooks and/or missing safety latches on cranes and hoists.

  Yes

  No

  N/A

• Crane pendant and radio controls are clearly marked and legible.

  Yes

  No

  N/A

• There are weight capacity labels on crane bridges, hoists, and hooks.

  Yes

  No

  N/A

• Capacity labels are visible or readable from the operators level.

  Yes

  No

  N/A

• Consistent capacities on cranes, hoists, and hooks, i.e. a 5-ton hook installed on a 1-ton hoist.

  Yes

  No

  N/A

• Seat belts are provided on all powered industrial trucks (fork trucks, mules, heavy equipment, etc.) that are provided with rollover protection.

  Yes

  No

  N/A

• There are no damaged conveyors.

  Yes

  No

  N/A

• Conveyors are equipped with emergency stop cables.

  Yes

  No

  N/A

• There are start-up alarms on automatic conveyors.

  Yes

  No

  N/A

Section A5 - Slings and Below the Hook Lifting Devices

• There is no evidence of any cut(s), punctured, abraded, knotted, damaged, etc., synthetic, wire rope, and chain slings.

  Yes

  No

  N/A

• There are no damaged C-hooks, slab handlers, forks, etc.

  Yes

  No

  N/A

• Below the hook lifting devices are labeled with capacity labeling.

  Yes

  No

  N/A

Section A6 - Emergency Equipment

• There are no obstructed eye washes, safety showers, and stretchers.

  Yes

  No

  N/A

• There are no obstructed fire extinguishers, fire hoses, fixed fire suppression system manual dump stations, fire alarms, etc.

  Yes

  No

  N/A

• Fire fighting equipment has evidence of a regular inspection.

  Yes

  No

  N/A

• There is no evidence of obstructed access to other emergency equipment, i.e. environmental spill kits & response carts, etc.

  Yes

  No

  N/A

• There is clear access to emergency escape respirators and they are in sanitary conditoin.

  Yes

  No

  N/A

Section B - Stock, Material & Chemicals

Section B1 - Raw Material, Work0in-Progress (WIP) and Chemicals

• There are no unstable or otherwise unsafe storage of process materials (raw materials, product, scrap, etc.)

  Yes

  No

  N/A

• There are no damaged containers that allow materials to spill out on the floor.

  Yes

  No

  N/A

Section B2 - Storerooms, Stockrooms & Storage Areas

• Good housekeeping in storerooms, stockrooms, and storage areas.

  Yes

  No

  N/A

• There is no storage of materials on top of cabinets and shelf units where employees can pull objects off onto their head.

  Yes

  No

  N/A

• There are no damaged storage racks.

  Yes

  No

  N/A

• Storage racks that are anchored to the floor or building structure.

  Yes

  No

  N/A

• Storage racks (other than small commercial rack units) labeled with loading capacity.

  Yes

  No

  N/A

• Good/clear access through storage areas that does not require employees to climb over materials.

  Yes

  No

  N/A

Section B3 - Chemical, Oil and Flammable Liquid Storage

• 'No Smoking' signs posted in flammable and combustible liquid storage areas.

  Yes

  No

  N/A

• There is grounding and/or bonding straps for flammable liquid storage, handling and transfer areas.

  Yes

  No

  N/A

• No mixed and otherwise unsafe storage of acids and bases.

  Yes

  No

  N/A

• The are practices of safe storage of chemicals in lab areas.

  Yes

  No

  N/A

• There are no old, expired, and/or obsolete chemicals in Lab(s).

  Yes

  No

  N/A

• There is appropriate PPE in chemical storage areas and laboratories.

  Yes

  No

  N/A

• Secondary containers are labeled, i.e. buckets/pails, cans, bottles, spray bottles, etc., not labeled to indicate contents.

  Yes

  No

  N/A

• Hazardous materials are stored properly considering material hazards and compatibility with other materials.

  Yes

  No

  N/A

Section B4 - Drum/Tote Management

• Individual drums/totes are labeled. Drums/totes are easily identifiable as to contents or empty conditions.

  Yes

  No

  N/A

• Stored drums/totes are properly sealed. In outside storage areas, bungs are not left open, tops are not left off so that rain and/or snow can accumulate inside the drums/totes, etc.

  Yes

  No

  N/A

• Drums/totes are not stored in areas within 75 feet of interior drains or storm drains.

  Yes

  No

  N/A

• Drums/totes are stored in an orderly fashion.

  Yes

  No

  N/A

• Drums/totes are in good condition, not dented, not broken, and not leaking.

  Yes

  No

  N/A

Section B5 - Compressed Gases

• Cylinders are secured in upright position with valve caps in place when in storage.

  Yes

  No

  N/A

• Oxygen and fuel gas cylinders, in storage, that are separated by 20 feet, or a 5 foot high wall with a ½-hour fire rating.

  Yes

  No

  N/A

• There are no damaged compressed gas cylinder gauges or hoses.

  Yes

  No

  N/A

• Cutting and welding units equipped with flashback arresters in the lines.

  Yes

  No

  N/A

• Oxygen-acetylene equipment unattended and not in use has pressure drained off on the regulators.

  Yes

  No

  N/A

Section C - Tools

Section C1 - Hand Tools

• Tools free of cracked or broken handles and other parts.

  Yes

  No

  N/A

• Tools do not have mushroomed heads (i.e., sledge wrench, chisel, etc.).

  Yes

  No

  N/A

• There are no homemade tools in use that have not been designed and approved by a qualified engineer (auditors should evaluate the tool's likelihood of failure during use).

  Yes

  No

  N/A

• Air nozzles equipped with safety tips that relieve air pressure when deadhead (pressure to relieve to 30 psi.or lower).

  Yes

  No

  N/A

• There were no unsafe tool use practices, i.e. employee using pliers instead of a wrench.

  Yes

  No

  N/A

Section C2 - Hand Held Power Tools & Power Cords

• Portable grinders are equipped with proper guards.

  Yes

  No

  N/A

• There are no damaged or cracked electrical tool cases.

  Yes

  No

  N/A

• There are no damaged or unsafe power cords, i.e. cut, spliced, crushed, punctured, etc.

  Yes

  No

  N/A

• There are no power cords pulled out of tool housing or plugs that expose wires.

  Yes

  No

  N/A

• Electric hand tools are equipped with ground plug or are double insulated.

  Yes

  No

  N/A

• Electric hand tools and extension cords with grounding prong inplace.

  Yes

  No

  N/A

• No evidence of homemade extension cords made from parts that were not recommended for that application by the<br>manufacturer.<br>

  Yes

  No

  N/A

• There are no electric tools and extension cords lying in water or wet areas.

  Yes

  No

  N/A

• Ground fault interrupters (GFI) in being used in areas prone to have water present (bathrooms, kitchens, exterior construction sites).

  Yes

  No

  N/A

• There is no evidence of tempoary wiring practices (i.e., extension cords used in lieu of permanent wiring).

  Yes

  No

  N/A

• Extension cords are not left in doorways where they can be damaged by a closing door.

  Yes

  No

  N/A

• There is no evidence of grinding non-ferrous metals with inappropriate stones.

  Yes

  No

  N/A

Section D - Walking Working Surfaces

Section D1 - Floors

• There is no evedence of water, oil, and other liquids creating slipping hazards on the floor.

  Yes

  No

  N/A

• No evidence of cracked, damaged, or severely uneven floors that present tripping hazards.

  Yes

  No

  N/A

• There are no tripping hazards created by power cords, hoses, etc., on the floor.

  Yes

  No

  N/A

• No material and/or equipment stored in aisleways.

  Yes

  No

  N/A

• Floor and wall openings and holes are protected to prevent a fall to a lower elevation.

  Yes

  No

  N/A

Section D2 - Stairs, Ladders & Platforms

• Stairs with four or more risers equipped with standard stair railings.

  Yes

  No

  N/A

• No evedence of power cords, hoses, tools, gloves, and other materials left on stairs that could create tripping hazards.

  Yes

  No

  N/A

• There were no damaged ladders or stair treads.

  Yes

  No

  N/A

• Ladders are not placed in an unsafe position while in use.

  Yes

  No

  N/A

• Portable ladders equipped with safety feet.

  Yes

  No

  N/A

• Platforms that are 4 foot high or higher equipped with standard railings and toe boards.

  Yes

  No

  N/A

• Scaffolds safely erected or used, i.e. standard railings and toeboards, inspected daily, no missing cleating on planks.

  Yes

  No

  N/A

• Elevated work platforms and crane bridges equipped with standard railing or personal fall protection provided.

  Yes

  No

  N/A

Section E - Buildings & Grounds

Section E1 - Exits

• Exits are marked and illuminated.

  Yes

  No

  N/A

• Emergency lighting functions.

  Yes

  No

  N/A

• Exit doors are not fitted with locks, sliding bolts, hooks, or any other device that prevents free discharge in an emergency.

  Yes

  No

  N/A

Section E2 - Lighting

• Good/sufficient interior and exterior lighting conditions.

  Yes

  No

  N/A

Section E3 - Piping Systems

• Pipe and valve systems are labeled properly with contents and direction of flow (color coding, flow direction indicators, labels, etc.)

  Yes

  No

  N/A

• Piping systems are supported properly and they are not sagging.

  Yes

  No

  N/A

• Emergency utility shut off valves are labeled.

  Yes

  No

  N/A

Section E4 - Interior Housekeeping

• Good storage practices of tools, equipment, hoses, power cords, materials, etc., inside buildings.

  Yes

  No

  N/A

• No evidence of accumulations of cigarette butts, ear plugs, debris, and spent materials on floors inside buildings; including, but not limited to, motor rooms, coolant cellars, mezzanines, above furnaces, basements, crane bridges, maintenance shops, contractor areas, vehicle garages, security buildings, water treatment facilities, training buildings, exercise rooms, conference rooms, etc.

  Yes

  No

  N/A

• There is no unsanitary conditions associated with food storage and preparation areas (cafeterias, kitchens, refrigerators, microwave ovens, vending machines, food storage cabinets, etc.)

  Yes

  No

  N/A

• There are no unsanitary water fountains.

  Yes

  No

  N/A

• There are no unsanitary conditions in bathrooms, locker rooms, and shower rooms.

  Yes

  No

  N/A

Section E5 - Exterior Housekeeping

• There are no haphazard storage of tools, equipment, hoses, power cords, materials, etc., on the ground outside buildings.

  Yes

  No

  N/A

• There is no accumulations of cigarette butts, ear plugs, debris, and spend materials on the ground outside buildings; including, but not limited to, parking lots, grounds, roadways, service roads, contractor areas, vehicle storage, etc.

  Yes

  No

  N/A

• There is no accumulations of cigarette butts, ear plugs, debris, and spend materials on roof tops.<br>• Unsafe accumulations of snow and ice on parking lots and sidewalks.

  Yes

  No

  N/A

Section E6 - Offices

• Good housekeeping practices in office areas, including: private offices, meeting rooms, copier rooms, computer rooms, restrooms, boiler rooms, electrical rooms, HVAC rooms, basements, storage rooms, closets, etc.

  Yes

  No

  N/A

• there are no overloaded extension cords and power strips.

  Yes

  No

  N/A

Section F - Environmental

F1 - Air Emissions

• There are no signs of releases of fugitive emissions on siding of overhead doors in plant (i.e. black staining or oily residue).

  Yes

  No

  N/A

• Volatile products are kept sealed when not in use.

  Yes

  No

  N/A

• Ventilation hoods are maintained.

  Yes

  No

  N/A

F2 - Water Quality

• Chemicals, oils, solids, and other pollutants are stored such that a spill could not reach storm water or process water drain.

  Yes

  No

  N/A

Section F3 - Spill Prevention & Containment

• Secondary containers of hazardous materials are not placed within 75 feet of an access to a storm or waste water sewer drain.

  Yes

  No

  N/A

• Transfer areas are properly labeled (i.e. pipe connections are labeled, instructions or proper transfer procedures are posted, emergency response procedures are posted).

  Yes

  No

  N/A

• Remote transfer areas are equipped with visual or audible overfill alarms and product level monitor displays.

  Yes

  No

  N/A

• Transfer areas have adequate secondary containment to prevent spills from entering the environment.<br>

  Yes

  No

  N/A

• Secondary containment at transfer areas are properly designed to contain spills associated with transfer operations (largest compartment on delivery vehicle and plant mobile equipment).

  Yes

  No

  N/A

• Tank systems are provided with adequate secondary containment.

  Yes

  No

  N/A

• Secondary containment areas have locked and valved drainage systems for 110% storage capacity of the largest container.

  Yes

  No

  N/A

• Storage tank containment system drainage hardware is maintained properly (i.e. valves are locked in the closed position, valves are not left open, valves open and close easily).

  Yes

  No

  N/A

• Spill kits are located within 75 feet of bulk chemical/oil transfer areas.

  Yes

  No

  N/A

Section F4 - Waste Management

• Wastes are stored in the proper designated area.

  Yes

  No

  N/A

• Wastes are properly segregated (i.e. incompatible wastes are not stored together such as waste acids and bases; recyclable wastes are mixed with trash).

  Yes

  No

  N/A

• Hazardous wastes are properly labeled or packaged per legal requirements.

  Yes

  No

  N/A

• Non-hazardous waste containers used to accumulate specific wastes (i.e. specific industrial waste, recyclables, scrap metal, fluorescent bulbs, etc.) within the plant are labeled.

  Yes

  No

  N/A

Section F5 - Energy

• Remelt and recycle furnace doors are maintained properly and are properly seated in the furnace sill

  Yes

  No

  N/A

• Furnace refractory is in good condition with no apparent hot spots

  Yes

  No

  N/A

• There is no apparent heat leakage on annealing and homogenizing/pusher furnace surfaces

  Yes

  No

  N/A

• Doors and windows are operational and seal properly

  Yes

  No

  N/A

• Compressed air systems and tools are in good condition with no apparent leakage

  Yes

  No

  N/A

• Insulation on process equipment and heated building space is in good condition

  Yes

  No

  N/A

Section G - Work Practices

Section G1 - Critical Practices

• Employees are following lockout/tagout procedures.

  Yes

  No

  N/A

• Employees are following confined space procedures.

  Yes

  No

  N/A

• Employees are not operating equipment with machine guarding defeated (tied back, light curtains turned off, limit switches taped down, etc.)

  Yes

  No

  N/A

• There are no Non-qualified persons working on or around live energized parts.

  Yes

  No

  N/A

Section G2 - Compliance & Rules

• Employees are complying with plant PPE rules (head, eyes/face, hearing, uniform requirements, hand, arm, foot, etc.)

  Yes

  No

  N/A

• Contractors, truck drivers, and visitors are complying with plant PPE rules (head, eyes/face, hearing, body, long sleve shirt, hand, arm, foot, etc.)

  Yes

  No

  N/A

• Contractors, truck drivers, and visitors are complying with general plant EH&S rules.

  Yes

  No

  N/A

Section G3 - Crane Operation

• Employees operating cranes and have completed pre-use inspection. Employees will be required to show the equipment has been inspected through documentation or demonstration.

  Yes

  No

  N/A

• An employee operating a crane that is in safe working condition (proper function of brakes, lights, warning devices, hydraulics, etc.)

  Yes

  No

  N/A

• Employees is safely operating a crane and is not putting others at risk.

  Yes

  No

  N/A

• Crane operator is not transporting loads over others.

  Yes

  No

  N/A

• Slings and below the hook lifting devices show no evidence of damage and are safe for use..

  Yes

  No

  N/A

• Operator is not exceeding equipment capacity limit.

  Yes

  No

  N/A

• Operator is not shock loading (sudden jerking lifts) the crane.

  Yes

  No

  N/A

• Operator is not side pulling loads.

  Yes

  No

  N/A

G4 - Fall Protection & Prevention

• Employees and contractors use all protection (full body harness, shock absorbing lanyard, engineered anchored points, or standard handrail system) when working above height of 4-feet of greater.

  Yes

  No

  N/A

• Trucks drivers use fall protection system for truck drivers untarping, loading, and tarping trucks.

  Yes

  No

  N/A

• Employees using fall protection that is good condition.

  Yes

  No

  N/A

• Employees and contractors working from aerial and scissor lifts are wearing a full body harness and lanyard attached to a designated anchor point on the equipment.

  Yes

  No

  N/A

Section G5 - Mobile Equipment

• Operator wearing seatbelt while operating mobile equipment (fork truck, scooters).

  Yes

  No

  N/A

• Operator traveling with forks 4-6 inches off the ground.

  Yes

  No

  N/A

• Operators are obeying traffic signs.

  Yes

  No

  N/A

• Operators are parking in designated areas and are parking in pedestrian walkway.

  Yes

  No

  N/A

• Operators are slowing down at corners and intersections.

  Yes

  No

  N/A

• Operator has completed a pre-use inspection of the equipment.

  Yes

  No

  N/A

• Pedestrians are using designated walkways.

  Yes

  No

  N/A