Information

  • Document No.

  • Audit Title

  • Client / Site

  • Conducted on

  • Prepared by

  • Location
  • Personnel

1. Safety Policy

  • 1:1 Is the mine's Safety Policy displayed publicly for all to see.

  • 1:2 Does the mine have a Safety Policy

  • 1:3 Is the Policy communicated at induction

2. Work Safety Management Plan.

  • 2:1 Is a Documented Safety Management Plan in place

  • 2:2 Is the plan approved by the Functional Manager

  • 2:3 Is the Safety Management Plan issued as a controlled document to supervisory staff and discussed accordingly with them.

3. Safe Work Instructions

  • 3:1 Have high/moderate risk activities been identified.

  • 3:2 Have JobSafety Analyses been carried out.

  • 3:3 Have Safe Work Instructions (SWIs) been developed

  • 3:4 Have SWIs & procedures been communicated to the workforce.

4. Subcontractors Safety Management.

  • 4:1 Has a Safety Management Plan been obtained from all contractors on site.

  • 4:2 Have the Plans been approve by the responsible Manager

  • 4:3 Have the Plans been implemented throughout the subcontractors team

  • 4:4 Are the subcontractors systems regularly audited

5. Investigations

  • 5:1 Is a system in place for reporting and investigating all accidents, incidents and non-conforances.

  • 5:2 Are all the relevant supervisors included in the reporting and investigation of the above

  • 5:3 Does the incident investigation system require checks in such laces as maintenance records, personal records, training records and production results to compare the number of repeat occurrences.

  • 5:4 Have the personnel who are required to conduct investigations been provided with formal training.

  • 5:5 Is corrective action carried out, within the allocated time, as recommended in the report

6. Safety Management System Review.

  • 6:1 is there a system in place for conducting comprehensive audits to check compliance with the safety management system

  • 6:2 Are audits conducted in accordance with the system.

  • 6:3 Are the findings of the review documented and actions formulated to address any identified deficiencies

  • 6:4 Are the actions corrected and approved by the agreed upon time frame

  • 6:5 Do senior management review the reports.

7. Training Systems -General (operational)

  • 7:1 Is a training system in place to develop and administer all training requirements.

  • 7:2 Has a clear career path been mapped out for operational personnel

  • 7:3 Is training aligned to the above career path (operations).

  • 7:4 Is the training aligned to the above career path.

  • 7:5 Has a systematic approach been used used to identify all employees training needs (training matrix) (operational)

  • 7:6 Do the instructors have the necessary competences for the specific topics in which they assess.

  • 7:7 Are the trainers given the necessary training to maintain their qualifications.

  • 7:8 Are lesson plans and effective training aids available and used for all the training programs.

  • 7:9 GOLD Are all aspects of training integrated into a singalong training management system to prevent duplication and manual manipulation of work.

  • 7:10 GOLD Does on-on-the job coaching form a part of the operator training programme.

  • 7:11 GOLD Are the defined career paths applied with operations personnel.

  • 7:12 GOLD Are the training requirements inter-linked with planned task observations and personnel assessments.

8. Site Inductiom

  • 8:1 Is an induction programme in place for new employees.

  • 8:2 Is the presenter, carrying out the training course, qualified to do so.

  • 8:3 Are all relevant and required topics covered in the induction.

  • 8:4 Are questionnaires completed by the learners.

  • 8:5 Is the induction well streamlined with minimal disruptions.

  • 8:6 Are records of induction completed and updated.

  • 8:7 Are all personnel on site inducted prior to commencing their duties.

  • 8:8 Is a specific induction program in place for supervisors.

  • 8:9 Is the content of the induction program adequate for the supervisory function.

  • 8:10 Have the supervisors completed induction questionnaires.

9. Supervisor Training.

  • 9:1 Is a specific training program in place for supervisors

  • 9:2 Does the program cover the basic requirements associated with the equipment and the mining process used throughout the mine

  • 9:3 Does the program cover fundamental elements of mechanised mining and supervision

  • 9:4 Does the program cover the basic soft skills associated with supervising the workforce (plan-do-check-act, leadership, delegation, mentoring etc)

  • 9:5 Do supervisors have a clearly defined career path available to follow.

  • 9:6 Is supervisor task training/assessments undertaken with supervisors.

  • 9:7 Are appropriate records pertaining to the above available.

  • 9:8 GOLD Are the supervisors evaluated using assessments on a regular basis (6 months)

  • 9:9 GOLD Have the majority of the supervisors attended the supervisory training courses

  • 9:10 GOLD Are defined career paths applied with the maintenance personnel.

  • 9:11 GOLD Are supervisors evaluated using Planned Task Observations.

10. External Certificates

  • 10:1 Do personnel in restricted occupations posses the required certificates of competency necessary to perform their tasks (winder certificate, electrical etc)

  • 10:2 Are copies of certificates available.

11. Competency Assessments.

  • 11:1 Are competency assessments performed across the required functions

  • 11:2 Are competency assessments performed on a regular, pre-defined basis

  • 11:3 Is the assessor performing the assessments qualified to do so.

  • 11:4 Are assessment records available.

  • 11:5 PLATINUM. Are competency assessments used to review individuals performance and define training needs.

12. Specific Skills.

  • 12:1 Is there a training program in place for maintenance personnel

  • 12:2 Has a clear career path been mapped out for the maintenance personnel.

  • 12:3 Is training aligned to the above career path (maintenance)

  • 12:4 Are programs updated whenever there are changes to systems of work or equipment.

  • 12:5 Are assessments regularly performed on the maintenance personnel.

  • 12:6 Are the above assessments records available

  • 12:7 GOLD Are all aspects of training integrated into a single training management system to prevent duplication and manual manipulation of work.

  • 12:8 GOLD Does on-the-job coaching form part of the maintenance training program.

  • 12:9 GOLD Are training requirements inter-linked with PJO and personnel assessments

13. Task Observations.

  • 13:1 Is a system in place which requires supervisors to conduct observations of tasks being performed

  • 13:2 Does the system ensure that all employees will be periodically observed whilst performing their required function

  • 13:3 Are the results of the observations clearly documented

  • 13:4 Are inspections in line with procedural compliance expectations

  • 13:5 GOLD. Is there a system to a sure that identified non-compliances are corrected

  • 13:6 GOLD. Are task observations linked to training/coaching needs and requirements

14. Group Communcation

  • 14:1 Is a group Communication system in place

  • 14:2 has responsibility been assigned to appropriate individuals for conducting these communication meetings

  • 14:3 Do all relevant personnel attend these communication meeting.

  • 14:4 Are minutes of these meetings taken and formally recorded on file

  • 14:5 Is a centralised control in place

  • 14:6 Is an effective communication system available throughout all working sections of the mine (with radios on all primary equipment)

  • 14:7 GOLD. Is there evidence of these meetings being used to review work practices and procedures.

  • 14:8 GOLD. Is a formalised communication system in place to discuss previous "planned v achieved" shift performance.

  • 14:9 GOLD. Is the control room used to effectively monitor and control the operation.

15. Pre-start Checks

  • 15:1 Are pre-start check lists developed and in place for all equipment.

  • 15:2 Are operators trained in the correct completion of these pre- start checks

  • 15:3 Are the pre-start checklist completed correctly each shift

  • 15:4 Are the completed pre-start check lists handed over to the maintenance department

  • 15:5 GOLD. Is the information from the pre-start check lists scheduled and the schedule communicated to the workforce on a daily basis

16. Emergency Preparedness

  • 16:1 Have the relevant types of emergencies bee identified

  • 16:2 Have emergency action plans been established

  • 16:3 Have the mine Coordinator and wardens been identified

  • 16:4 Has the evacuation plan/routes been displayed at all waiting places

  • 16:5 Is emergency awareness training conducted.

  • 16:6 Are all refuge chambers and emergency routes sufficiently visible throughout the mine

  • 16:7 Is the emergency procedure regularly rehearsed

17. Equipment Selection

  • 17:1 Has a review been conducted to determine the equipment specifications required to ensure production targets are met within the given mining environment

  • 17.2.Does the review take into account availability of spare parts and consumables?

  • 17.3.Has equipment been purchased in accordance with the review?

  • 17.4. Are frontline personnel involved in the equipment selection process

  • 17.5. GOLD Are follow-up reviews conducted to evaluate previous decisions and future requirements based on planned vs. actual.

18. CONSUMABLES (Rock Tools)

  • 18.1.Has a list of critical consumables been for each machine type?

  • 18.2.Have minimum stock levels been determined?

  • 18.3.Has responsibilities been assigned to correctly manage stock levels?

  • 18.5.Is consumable usage formally reported on a monthly basis?

  • 18.4. GOLD Is usage monitored taking into account performance achieved and expenditure vs. budget?

  • 18.5. GOLD Are stock-outs measured and used to update minimum stock levels.

  • 18.6. GOLD Is consumables consumption used to evaluate individuals performance and integrated into a performance appraisal system.

19. PLANNING - LONG TERM

  • 19.1.Does the organisation have a long-term production plan in place?

  • 19.2.Does the long-term plan reflect the original business plan that was compiled to allow funding for the operation to proceed?

  • 19.3.Is the long term production plan updated at least monthly to show actual meters excavated?

  • 19.4.Where an obvious production shortfall occurs has the organisation developed an action plan to remedy the situation?

  • 19.5.Does the long term plan take into account tipping points and tramming distances?

20. PLANNING - MONTHLY

  • 20.1.Is there a system in place to ensure formal planning is conducted monthly?

  • 20.2.Are all appropriate positions/people involved in the determination of the monthly plan?

  • 20.3.Are clear production targets established within the monthly plan?

  • 20.5.Does the short-term plan reflect the requirements of the long-term plan?

  • 20.6.Are all relevant mine measurements incorporated into the monthly plan?

  • 20.4. GOLD Are production shortfalls from previous months taken into account?

  • 20.5. GOLD Is a Lost Blast Analysis conducted to determine shortfalls in production and reasons for not achieving the plan.

  • 20.6. OLD Is a "planned vs. achieved" analysis carried out to determine compliance with the monthly plan.

21. PLANNING - DAILY

  • 21.1.Is there a system in place to ensure daily production expectations are planned with the supervisors?

  • 21.2.Is the daily plan directly aligned with the monthly plan?

  • 21.3.Do all supervisors and leading hands receive a copy of the daily plan?

  • 21.4.Are planned versus actual activities recorded at the end of each shift?

  • 21.5.Is the monthly production plan updated daily?

  • 21.6.Is the actual production information used to identify trends and assist in problem solving?

  • 21.7 GOLD Is a "planned vs. achieved" analysis carried out to determine compliance with the daily plan.

  • 21.8. GOLD Is the achieved production and development within 80% compliance of the plan.

  • 21.9. GOLD Is a Lost Blast Analysis conducted per day to determine production and development deficiencies.

22. PLANNING - SHIFT

  • 22.1.Is there an appropriate pre-shift meeting with all the necessary members of the team?

  • 22.2.Is the pre-shift meeting conducted in a quiet area, record kept, with appropriate visual aids for the capturing and communication of critical information?

  • 22.3.Is the information updated (and accurate) at the end of each shift by the off going supervisor?

  • 22.4.Does the communicated information reflect the requirements of the 24 hour cycle plan?

  • 22.5. GOLD Is a Lost Blast Analysis conducted per shift to determine production and development deficiencies.

23. SHIFT PERFORMANCE MEASUREMENT

  • 23.1.Have shift performance measurement parameter requirements been determined for each piece of equipment?

  • 23.2.Have these expectations been communicated to the team?

  • 23.3.Is the equipment capable of achieving the required performance measures/parameters?

  • 23.4. GOLD Are the performance parameters correctly monitored and communicated to all parties concerned?

  • 23.5. GOLD Is action taken when KPIs not to expectation?

  • 23.6. GOLD Is shift performance collated into monthly and annual performance information (per person).

  • 23.7 GOLD Do individuals receive feedback regarding their daily and monthly performance and any related deficiencies.

24. MAINTENANCE - GENERAL

  • 24.1.Is a maintenance strategy defined.

  • 24.2.Is a maintenance philosophy defined.

  • 24.3.Do maintenance staff know what the meaning and purpose of the above are?

  • 24.4.Is information from the Pre-start checks captured and scheduled? (Backlogs created)

  • 24.7.Are sufficient maintenance personnel available for breakdown requirements?

  • 24.8.Are sufficient means of communication available for the breakdown crews to operate effectively?

  • 24.9.Are breakdown personnel able to respond in a timely fashion?

  • 24.5. GOLD Has a review been conducted to determine the personnel skills and compliments required?

  • 24.6. GOLD Have the review findings been complied with?

  • 24.7. GOLD Have the maintenance strategy and philosophy been applied (as defined)

25. MAINTENANCE - WORKSHOP

  • 25.1.Is the structure of the workshop adequate for the maintenance requirements?

  • 25.2.Are appropriate ablutions available for workshop personnel?

  • 25.3.Is adequate tooling available with reference to the machinery on site?

  • 25.4.Is an in-line Oils and lubricants delivery system in place (borehole)?

  • 25.5. Are oils and lubes transported using drums (underground to surface)

  • 25.6.Is Oil and Diesel consumption measured?

  • 25.7.Can ‘used’ lubricates be disposed of correctly?

  • 25.8.Is Electrical power available for specific equipment?

  • 25.9. GOLD Has a workshop review conducted annually to determine workshop requirements given changes in production demands and machine fleet sizes.

  • 25.10. GOLD Has the above assessment been complied with

  • 25.11. GOLD Has an assessment been conducted to determine optimum location of the main workshop and main workshop requirements

26. MAINTENANCE - SPARES ON SITE

  • 26.1.Is a critical spares list in place for every machine on site?

  • 26.2.Is the critical spares list reviewed and updated?

  • 26.3.Is a person responsible for spares issuing and monitoring of spares?

  • 26.4.Is a person responsible for spares ordering?

  • 26.5.Are stores facilities adequate for the required spares (sufficient stores with security, ventilation, shelving etc)

  • 26.6.Are all stores and spares personnel adequately trained to manage, issue and monitor spares

  • 26.7.Are minimum stock levels determined?

  • 26.8.Are stock levels maintained according to the spares requirements?

  • 26.9.Are parts costs reconciled and reported?

  • 26.10.Are planned materials (parts) ordered and linked to a Work Order prior to the work being scheduled?

  • 26.11.Is there a stock procurement procedure in place?

  • 26.12. Is there an emergency parts ordering procedure in place?

  • 26.13. Are lead times recorded and considered in the procurement process?

  • 26.14 Are the contractors parts ordering procedure known by the mine?

  • 26.15. GOLD Are stock outs measured?

  • 26.16. GOLD Are late deliveries measured?

  • 26.17. GOLD Is a computerised stores management system in place for all stores?

  • 26.18. GOLD Is the stock procurement procedure adhered to?

  • 26.19. GOLD Are stock levels evaluated on a 6 monthly basis to ensure current consumption is aligned with spares requirements.

26. MAINTENANCE - SPARES SHARED SERVICES

  • 26.1.Is a critical spares list in place for every machine on site?

  • 26.2.Is the critical spares list reviewed and updated?

  • 26.3.Is a person responsible for spares issuing and monitoring of spares?

  • 26.4.Is a person responsible for spares ordering?

  • 26.5.Are stores facilities adequate for the required spares (sufficient stores with security, ventilation, shelving etc)

  • 26.6.Are all stores and spares personnel adequately trained to manage, issue and monitor spares

  • 26.7.Are minimum stock levels determined?

  • 26.8.Are stock levels maintained according to the spares requirements?

  • 26.9.Are parts costs reconciled and reported?

  • 26.10.Are planned materials (parts) ordered and linked to a Work Order prior to the work being scheduled?

  • 26.11.Is there a stock procurement procedure in place?

  • 26.12. Is there an emergency parts ordering procedure in place?

  • 26.13. Are lead times recorded and considered in the procurement process?

  • 26.14 Are the contractors parts ordering procedure known by the mine?

  • 26.15. GOLD Are stock outs measured?

  • 26.16. GOLD Are late deliveries measured?

  • 26.17. GOLD Is a computerised stores management system in place for all stores?

  • 26.18. GOLD Is the stock procurement procedure adhered to?

  • 26.19. GOLD Are stock levels evaluated on a 6 monthly basis to ensure current consumption is aligned with spares requirements.

27. MAINTENANCE - PERFORMANCE MEASUREMENT

  • 27.1.Has a review been conducted to determine performance measurement KPIs?

  • 27.2.Are the approved KPIs documented and distributed to all involved?

  • 27.3.Are the KPIs formally reported on?

  • 27.4.Is there a formal Root Cause Failure analysis process in place?

  • 27.5.Are chronic failures identified and addressed, i.e. is there a continuous improvement action plan in place?

  • 27.6.Is the equipment Availability measured and analysed (trended)?

  • 27.7. Is the Planned Vs Unplanned Work Ratio documened and reported?

  • 27.8. Is there a Backlog board in place?

  • 27.9.  Is the backlog board updated daily?

  • 27.10.  Is a weekly maintenance plan issued to the maintenance staff (supervisors & artisans) prior to the week commencing?

  • 27.11. GOLD Is the equipment MTTR measured and analysed (trended)?

  • 27.12. GOLD Is the equipment MTBF measured and analysed (trended)?

  • 27.13. GOLD Is the equipment Labour utilisation measured and analysed (trended)?

  • 27.14. GOLD Are top ten cost items identified and reported per machine type per month

  • 27.15. GOLD Is the root cause failure programme resulting in improved reliability and/or reduced costs.

  • 27.16. GOLD Are Planned versus Unplanned works ratios understood and proactively managed.

  • 27.17. GOLD Are top ten downtime items identified and reported per machine type per month

28. OPERATIONS - STANDARDS

  • 28.1.Have work place standards been documented?

  • 28.2.Have they been approved by the responsible manager?

  • 28.3.Have the standards been communicated to all applicable personnel?

  • 28.4.Are formal inspections conducted to measure compliance with the standards?

29. OPERATIONS - SURVEY

  • 29.1.Are survey plans available for all areas of development?

  • 29.2.Are special instructions noted on plans where applicable?

  • 29.3.Do all relevant departments approve plans prior to their final release?

  • 29.4.Are the survey plans issued to all necessary personnel?

30. OPERATIONS - KPIs

  • 30.1.Have Key performance indicators been determined and documented?

  • 30.2.Do all pieces of equipment been assigned KPIs?

  • 30.3.Have the KPIs been communicated to all personnel involved?

  • 30.4.Are KPIs measured and formally reported on?

  • 30.5. GOLD Is action taken when KPIs not to expectation?

  • 30.6. GOLD Do individuals receive feedback regarding their daily and monthly performance and any related deficiencies.

31. OPERATIONS - SYSTEM OVERVIEW

  • 31.1.Is there a system in place for conducting unbiased audits?

  • 31.2.Are previous Audit reports available?

  • 31.3.Have Action Plans been established, based on the findings of these Audits?

  • 31.4.Have the above action plans been approved and implemented?

  • 31.5. GOLD Is system performance tracked and trended on a monthly basis

  • 31.6. GOLD Is the system used as a tool for continuous improvement

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