Title Page
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Document No.1.0
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Audit Title
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KLSM Telupid
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5 - 6 January 2016
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Ouzza Ndy Dominic
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Effluent Site
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Cassey Leonardus G Toyu
1.0 - Previous Inspection
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1.1 - Has the last inspection been reviewed?
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1.2 - Are there any outstanding action?
2.0 - Grading
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2.1 - Has the 50 random grading being practiced for lorries less than 5 tonnes?
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2.2 - Has the 10 random grading being practiced for lorries more than 5 tonnes?
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2.3 - Has it call up for joint grading at mill / estate platform?
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2.4 - Has bunch marking to trace the errant harvester been practiced hence deter the unripe bunch?
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2.5 - Has the quality bonus been practiced for the supplier on trip by trip basis?
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2.6 - Has the incentive reached to the staff and foreman?
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2.7 - Make sure that there is no unsafe act / condition.
3.0 - Production Process Control – OER
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3.1 - Are the oil losses on the press fibre < 7.3% OLDM & < 4.5% OLWB?
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3.2 - Are the oil losses on the sludge < 13% OLDM & < 0.8% OLWB?
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3.3 - Are the oil losses in the sterilizer < 0.8% OLWB?
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3.4 - Are the oil losses on the nut < 0.6% OLWB?
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3.5 - Are the unstripped bunches < 3%?
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3.6 - Make sure that there is no unsafe act / condition.
4.0 - Production Process Control - KER
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4.1 - Are the kernel losses in the cyclone fiber <1% ?<br>
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4.2 - Are the kernel losses in the dry shell < 2%?
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4.3 - Are the kernel losses in the wet shell < 2%?
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4.4 - Are the unstripped bunches < 3%?
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4.5 - Are the broken nut to total nut in the press cake < 15%?
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4.6 - Make sure that there is no unsafe act / condition.
5.0 - Engineering Control
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5.1 - Big sample of 5 kg for checking kernel losses in cyclone fiber.<br>
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5.2 - Use of thick bottom ni-hard discharge & cone.
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5.3 - Use of 6” x 6” hydrocyclone pump.
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5.4 - Expansion column for depericarper.
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5.5 - Has bunch crushing / double threshing been practiced?<br>
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5.6 - Has steam pipe design ripple mill for efficiency of nut cracking (efficiency > 98%)?
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5.7 - Has the expansion column or cracked window for cracked mixture winnower?
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5.8 - Has continuous training for mill operator & staff been practiced? <br>
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5.9 - Make sure that there is no unsafe act / condition.
6.0 - External Risk – Security Of Palm Product
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6.1 - Has inspection for the tanker been carried out? <br>
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6.2 - Does a security standby behind the weightbridge to monitor the tanker and kernel trailer?
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6.3 - Has the net weight been monitored by the dispatch with flowmeter against the weightbridge?
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6.4 - Has the in tag security sealed all the manhole and outlet?
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6.5 - Has the gate pass, DN and PL3 been formed in place and applied?
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6.6 - Has the CCTV been placed at site and at the weightbridge?
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6.7 - Has the tanker been installed with GPS systems?
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6.8 - Is the transits insurance in place for each tanker and trailer?
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6.9 - Have the tests for FFA, moisture, impurities, and DOBI been carried out for the CPO?
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6.10 - Has the trailer compartment been inspected by the security personnel?
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6.11 - Make sure that the loaded PK is not excessive and leveled with the trailer body.<br>
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6.12 - Has the canvas been secured and locked with link chain and security sealed?
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6.13 - Has the gate pass been incorporated with DN?
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6.14 - Has the test been carried out for the FFA, moisture, impurities and DOBI for the CPO?
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6.15 - Make sure that there is no unsafe act / condition.
7.0 - Optimize Efficiency Of Mill & Reduce Risk Of Stopping In Production Shift Runs.
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7.1 - Is there a sufficient storage capacity for CPO and timing off take of the end product? <br>
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7.2 - Is there a sufficient storage capacity for PK and timing off take of the end product?
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7.3 - Is the downtime > 4%?
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7.4 - Has the good preventive maintenance schedule been implemented?
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7.5 - Has the DOE standard on smoke density been achieved? (Regimen 2 & CMS)<br>
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7.6 - Has the DOE standard of BOD < 20ppm been achieved? <br>
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7.7 - Has the DOE standard for zero spillage at the land irrigation been achieved?
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7.8 - Has the maximum threshold level for the kernel arrived?
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7.9 - Has the maximum threshold level for the CPO arrived?
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7.10 - Is there any lack of coordination between the marketing and mill?
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7.11 - Is there a minimum spare part available for implementation?
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7.12 - Make sure that there is no unsafe act / condition.
8.0 - Major / Critical Machinery Breakdown Prevention
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8.1 - Has a proper preventive measurement been implemented? <br>
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8.2 - Has a proper RH base preventive measurement been implemented?
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8.3 - Is there a proper boiler water logsheet?
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8.4 - Has the root cause been traced and adequate capacity for supporting equipment (e.g. softener & daerator) been ensured?
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8.5 - Has the contract service schedule been implemented?
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8.6 - Is there any measuring tools (e.g. vibration meter)?
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8.7 - Has the documentation been carried out for all maintenance and safety procedure?
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8.8 - Has the documentation been carried out for raw water and boiler water treatment?
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8.9 - Is there a weekly communication with the HOD on mill operation?
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8.10 - Is there a sufficient stock of water for dry month ?
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8.11 - Is there any competent contractor appointed to do a thorough checking on the weighbridge, water treatment and boiler water treatment, boiler and steam turbine?
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8.12 - Has the proper SOP been trained by in-house / outside trainer?
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8.13 - Make sure that there is no unsafe act / condition.
9.0 - Cost Efficiency / Competitiveness
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9.1 - Is there any daily dispatch records to monitor the stock level and storage capacity?
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9.2 - Is there a proper schedule for oil dispatch?
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9.3 - Is there a quality control in place to minimize rejection or penalty?
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9.4 - Has the rejection target of 0% been achieved?
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9.5 - Is there an internal store documentation<br>(e.g. PR)?
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9.6 - Has the stock card record been maintained?
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9.7 - Is there a running hour machine installed to schedule maintenance and to indicate the life span of the part?
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9.8 - Is there any manual for daily cost monitoring using a book keeping?
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9.9 - Is there any monthly cost analysis, accounts review & machinery report?
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9.10 - Has the store practiced the no replacement without returning the former items ?
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9.11 - Is the store keeper keeping track of the minimum and maximum stock level for specific items? <br>
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9.12 - Has the manual machinery history card been implemented or the excel spreadsheet been used?
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9.13 - Make sure that there is no unsafe act / condition.
10.0 - Mill Throughput Matter
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10.1 - Is there a deadline for the submission of daily production report?
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10.2 - Have the bottlenecks of the machinery been identified? Rectify the cause.
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10.3 - Is there a daily and weekly discussion between the executive and supervisor?
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10.4 - Has the management stricten the procedure for overtime?
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10.5 - Is the downtime and breakdown report being monitored weekly and monthly?
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10.6 - Has the machinery running hour report been implemented and reviewed daily?
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10.7 - Make sure that there is no unsafe act / condition.
11.0 - Compliance To Statutory Requirement (DOE, DOSH, MPOB, JBE, Bomba)
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11.1 - Is the competent laboratory report being carried out biweekly?
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11.2 - Has the discharge maintained a correct loading in accordance to design capacity?
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11.3 - Has the SHC been established?
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11.4 - Has the annual inspection been carried out based on DOSH?
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11.5 - Has the CHRA been carried out?
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11.6 - Has the noise monitoring been carried out ?
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11.7 - Has the in-house safety talk been carried out by the management?
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11.8 - Has the internal safety audit been carried out?
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11.9 - Has the quarterly submission to government body like DOE been carried out?<br>
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11.10 - Has an independent lab been engaged especially for the test sample related to the DOE matter?
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11.11 - Make sure that there is no unsafe act / condition.
Sign off
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On-site Representative
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Auditor's Signature
