Information
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Document No.
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Audit Title
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Client / Site
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Conducted on
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Prepared by
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Location
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Personnel
1. Safety Policy
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1:1 Is the mine's Safety Policy displayed publicly for all to see.
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1:2 Does the mine have a Safety Policy
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1:3 Is the Policy communicated at induction
2. Work Safety Management Plan.
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2:1 Is a Documented Safety Management Plan in place
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2:2 Is the plan approved by the Functional Manager
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2:3 Is the Safety Management Plan issued as a controlled document to supervisory staff and discussed accordingly with them.
3. Safe Work Instructions
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3:1 Have high/moderate risk activities been identified.
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3:2 Have JobSafety Analyses been carried out.
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3:3 Have Safe Work Instructions (SWIs) been developed
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3:4 Have SWIs & procedures been communicated to the workforce.
4. Subcontractors Safety Management.
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4:1 Has a Safety Management Plan been obtained from all contractors on site.
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4:2 Have the Plans been approve by the responsible Manager
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4:3 Have the Plans been implemented throughout the subcontractors team
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4:4 Are the subcontractors systems regularly audited
5. Investigations
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5:1 Is a system in place for reporting and investigating all accidents, incidents and non-conforances.
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5:2 Are all the relevant supervisors included in the reporting and investigation of the above
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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.
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5:4 Have the personnel who are required to conduct investigations been provided with formal training.
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5:5 Is corrective action carried out, within the allocated time, as recommended in the report
6. Safety Management System Review.
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6:1 is there a system in place for conducting comprehensive audits to check compliance with the safety management system
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6:2 Are audits conducted in accordance with the system.
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6:3 Are the findings of the review documented and actions formulated to address any identified deficiencies
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6:4 Are the actions corrected and approved by the agreed upon time frame
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6:5 Do senior management review the reports.
7. Training Systems -General (operational)
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7:1 Is a training system in place to develop and administer all training requirements.
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7:2 Has a clear career path been mapped out for operational personnel
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7:3 Is training aligned to the above career path (operations).
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7:4 Is the training aligned to the above career path.
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7:5 Has a systematic approach been used used to identify all employees training needs (training matrix) (operational)
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7:6 Do the instructors have the necessary competences for the specific topics in which they assess.
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7:7 Are the trainers given the necessary training to maintain their qualifications.
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7:8 Are lesson plans and effective training aids available and used for all the training programs.
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7:9 GOLD Are all aspects of training integrated into a singalong training management system to prevent duplication and manual manipulation of work.
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7:10 GOLD Does on-on-the job coaching form a part of the operator training programme.
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7:11 GOLD Are the defined career paths applied with operations personnel.
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7:12 GOLD Are the training requirements inter-linked with planned task observations and personnel assessments.
8. Site Inductiom
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8:1 Is an induction programme in place for new employees.
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8:2 Is the presenter, carrying out the training course, qualified to do so.
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8:3 Are all relevant and required topics covered in the induction.
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8:4 Are questionnaires completed by the learners.
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8:5 Is the induction well streamlined with minimal disruptions.
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8:6 Are records of induction completed and updated.
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8:7 Are all personnel on site inducted prior to commencing their duties.
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8:8 Is a specific induction program in place for supervisors.
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8:9 Is the content of the induction program adequate for the supervisory function.
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8:10 Have the supervisors completed induction questionnaires.
9. Supervisor Training.
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9:1 Is a specific training program in place for supervisors
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9:2 Does the program cover the basic requirements associated with the equipment and the mining process used throughout the mine
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9:3 Does the program cover fundamental elements of mechanised mining and supervision
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9:4 Does the program cover the basic soft skills associated with supervising the workforce (plan-do-check-act, leadership, delegation, mentoring etc)
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9:5 Do supervisors have a clearly defined career path available to follow.
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9:6 Is supervisor task training/assessments undertaken with supervisors.
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9:7 Are appropriate records pertaining to the above available.
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9:8 GOLD Are the supervisors evaluated using assessments on a regular basis (6 months)
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9:9 GOLD Have the majority of the supervisors attended the supervisory training courses
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9:10 GOLD Are defined career paths applied with the maintenance personnel.
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9:11 GOLD Are supervisors evaluated using Planned Task Observations.
10. External Certificates
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10:1 Do personnel in restricted occupations posses the required certificates of competency necessary to perform their tasks (winder certificate, electrical etc)
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10:2 Are copies of certificates available.
11. Competency Assessments.
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11:1 Are competency assessments performed across the required functions
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11:2 Are competency assessments performed on a regular, pre-defined basis
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11:3 Is the assessor performing the assessments qualified to do so.
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11:4 Are assessment records available.
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11:5 PLATINUM. Are competency assessments used to review individuals performance and define training needs.
12. Specific Skills.
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12:1 Is there a training program in place for maintenance personnel
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12:2 Has a clear career path been mapped out for the maintenance personnel.
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12:3 Is training aligned to the above career path (maintenance)
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12:4 Are programs updated whenever there are changes to systems of work or equipment.
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12:5 Are assessments regularly performed on the maintenance personnel.
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12:6 Are the above assessments records available
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12:7 GOLD Are all aspects of training integrated into a single training management system to prevent duplication and manual manipulation of work.
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12:8 GOLD Does on-the-job coaching form part of the maintenance training program.
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12:9 GOLD Are training requirements inter-linked with PJO and personnel assessments
13. Task Observations.
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13:1 Is a system in place which requires supervisors to conduct observations of tasks being performed
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13:2 Does the system ensure that all employees will be periodically observed whilst performing their required function
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13:3 Are the results of the observations clearly documented
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13:4 Are inspections in line with procedural compliance expectations
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13:5 GOLD. Is there a system to a sure that identified non-compliances are corrected
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13:6 GOLD. Are task observations linked to training/coaching needs and requirements
14. Group Communcation
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14:1 Is a group Communication system in place
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14:2 has responsibility been assigned to appropriate individuals for conducting these communication meetings
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14:3 Do all relevant personnel attend these communication meeting.
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14:4 Are minutes of these meetings taken and formally recorded on file
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14:5 Is a centralised control in place
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14:6 Is an effective communication system available throughout all working sections of the mine (with radios on all primary equipment)
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14:7 GOLD. Is there evidence of these meetings being used to review work practices and procedures.
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14:8 GOLD. Is a formalised communication system in place to discuss previous "planned v achieved" shift performance.
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14:9 GOLD. Is the control room used to effectively monitor and control the operation.
15. Pre-start Checks
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15:1 Are pre-start check lists developed and in place for all equipment.
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15:2 Are operators trained in the correct completion of these pre- start checks
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15:3 Are the pre-start checklist completed correctly each shift
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15:4 Are the completed pre-start check lists handed over to the maintenance department
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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
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16:1 Have the relevant types of emergencies bee identified
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16:2 Have emergency action plans been established
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16:3 Have the mine Coordinator and wardens been identified
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16:4 Has the evacuation plan/routes been displayed at all waiting places
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16:5 Is emergency awareness training conducted.
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16:6 Are all refuge chambers and emergency routes sufficiently visible throughout the mine
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16:7 Is the emergency procedure regularly rehearsed
17. Equipment Selection
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17:1 Has a review been conducted to determine the equipment specifications required to ensure production targets are met within the given mining environment
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17.2.Does the review take into account availability of spare parts and consumables?
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17.3.Has equipment been purchased in accordance with the review?
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17.4. Are frontline personnel involved in the equipment selection process
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17.5. GOLD Are follow-up reviews conducted to evaluate previous decisions and future requirements based on planned vs. actual.
18. CONSUMABLES (Rock Tools)
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18.1.Has a list of critical consumables been for each machine type?
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18.2.Have minimum stock levels been determined?
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18.3.Has responsibilities been assigned to correctly manage stock levels?
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18.5.Is consumable usage formally reported on a monthly basis?
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18.4. GOLD Is usage monitored taking into account performance achieved and expenditure vs. budget?
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18.5. GOLD Are stock-outs measured and used to update minimum stock levels.
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18.6. GOLD Is consumables consumption used to evaluate individuals performance and integrated into a performance appraisal system.
19. PLANNING - LONG TERM
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19.1.Does the organisation have a long-term production plan in place?
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19.2.Does the long-term plan reflect the original business plan that was compiled to allow funding for the operation to proceed?
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19.3.Is the long term production plan updated at least monthly to show actual meters excavated?
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19.4.Where an obvious production shortfall occurs has the organisation developed an action plan to remedy the situation?
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19.5.Does the long term plan take into account tipping points and tramming distances?
20. PLANNING - MONTHLY
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20.1.Is there a system in place to ensure formal planning is conducted monthly?
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20.2.Are all appropriate positions/people involved in the determination of the monthly plan?
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20.3.Are clear production targets established within the monthly plan?
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20.5.Does the short-term plan reflect the requirements of the long-term plan?
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20.6.Are all relevant mine measurements incorporated into the monthly plan?
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20.4. GOLD Are production shortfalls from previous months taken into account?
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20.5. GOLD Is a Lost Blast Analysis conducted to determine shortfalls in production and reasons for not achieving the plan.
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20.6. OLD Is a "planned vs. achieved" analysis carried out to determine compliance with the monthly plan.
21. PLANNING - DAILY
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21.1.Is there a system in place to ensure daily production expectations are planned with the supervisors?
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21.2.Is the daily plan directly aligned with the monthly plan?
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21.3.Do all supervisors and leading hands receive a copy of the daily plan?
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21.4.Are planned versus actual activities recorded at the end of each shift?
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21.5.Is the monthly production plan updated daily?
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21.6.Is the actual production information used to identify trends and assist in problem solving?
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21.7 GOLD Is a "planned vs. achieved" analysis carried out to determine compliance with the daily plan.
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21.8. GOLD Is the achieved production and development within 80% compliance of the plan.
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21.9. GOLD Is a Lost Blast Analysis conducted per day to determine production and development deficiencies.
22. PLANNING - SHIFT
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22.1.Is there an appropriate pre-shift meeting with all the necessary members of the team?
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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?
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22.3.Is the information updated (and accurate) at the end of each shift by the off going supervisor?
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22.4.Does the communicated information reflect the requirements of the 24 hour cycle plan?
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22.5. GOLD Is a Lost Blast Analysis conducted per shift to determine production and development deficiencies.
23. SHIFT PERFORMANCE MEASUREMENT
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23.1.Have shift performance measurement parameter requirements been determined for each piece of equipment?
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23.2.Have these expectations been communicated to the team?
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23.3.Is the equipment capable of achieving the required performance measures/parameters?
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23.4. GOLD Are the performance parameters correctly monitored and communicated to all parties concerned?
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23.5. GOLD Is action taken when KPIs not to expectation?
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23.6. GOLD Is shift performance collated into monthly and annual performance information (per person).
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23.7 GOLD Do individuals receive feedback regarding their daily and monthly performance and any related deficiencies.
24. MAINTENANCE - GENERAL
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24.1.Is a maintenance strategy defined.
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24.2.Is a maintenance philosophy defined.
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24.3.Do maintenance staff know what the meaning and purpose of the above are?
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24.4.Is information from the Pre-start checks captured and scheduled? (Backlogs created)
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24.7.Are sufficient maintenance personnel available for breakdown requirements?
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24.8.Are sufficient means of communication available for the breakdown crews to operate effectively?
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24.9.Are breakdown personnel able to respond in a timely fashion?
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24.5. GOLD Has a review been conducted to determine the personnel skills and compliments required?
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24.6. GOLD Have the review findings been complied with?
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24.7. GOLD Have the maintenance strategy and philosophy been applied (as defined)
25. MAINTENANCE - WORKSHOP
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25.1.Is the structure of the workshop adequate for the maintenance requirements?
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25.2.Are appropriate ablutions available for workshop personnel?
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25.3.Is adequate tooling available with reference to the machinery on site?
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25.4.Is an in-line Oils and lubricants delivery system in place (borehole)?
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25.5. Are oils and lubes transported using drums (underground to surface)
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25.6.Is Oil and Diesel consumption measured?
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25.7.Can ‘used’ lubricates be disposed of correctly?
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25.8.Is Electrical power available for specific equipment?
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25.9. GOLD Has a workshop review conducted annually to determine workshop requirements given changes in production demands and machine fleet sizes.
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25.10. GOLD Has the above assessment been complied with
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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
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26.1.Is a critical spares list in place for every machine on site?
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26.2.Is the critical spares list reviewed and updated?
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26.3.Is a person responsible for spares issuing and monitoring of spares?
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26.4.Is a person responsible for spares ordering?
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26.5.Are stores facilities adequate for the required spares (sufficient stores with security, ventilation, shelving etc)
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26.6.Are all stores and spares personnel adequately trained to manage, issue and monitor spares
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26.7.Are minimum stock levels determined?
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26.8.Are stock levels maintained according to the spares requirements?
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26.9.Are parts costs reconciled and reported?
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26.10.Are planned materials (parts) ordered and linked to a Work Order prior to the work being scheduled?
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26.11.Is there a stock procurement procedure in place?
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26.12. Is there an emergency parts ordering procedure in place?
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26.13. Are lead times recorded and considered in the procurement process?
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26.14 Are the contractors parts ordering procedure known by the mine?
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26.15. GOLD Are stock outs measured?
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26.16. GOLD Are late deliveries measured?
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26.17. GOLD Is a computerised stores management system in place for all stores?
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26.18. GOLD Is the stock procurement procedure adhered to?
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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
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26.1.Is a critical spares list in place for every machine on site?
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26.2.Is the critical spares list reviewed and updated?
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26.3.Is a person responsible for spares issuing and monitoring of spares?
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26.4.Is a person responsible for spares ordering?
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26.5.Are stores facilities adequate for the required spares (sufficient stores with security, ventilation, shelving etc)
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26.6.Are all stores and spares personnel adequately trained to manage, issue and monitor spares
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26.7.Are minimum stock levels determined?
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26.8.Are stock levels maintained according to the spares requirements?
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26.9.Are parts costs reconciled and reported?
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26.10.Are planned materials (parts) ordered and linked to a Work Order prior to the work being scheduled?
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26.11.Is there a stock procurement procedure in place?
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26.12. Is there an emergency parts ordering procedure in place?
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26.13. Are lead times recorded and considered in the procurement process?
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26.14 Are the contractors parts ordering procedure known by the mine?
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26.15. GOLD Are stock outs measured?
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26.16. GOLD Are late deliveries measured?
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26.17. GOLD Is a computerised stores management system in place for all stores?
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26.18. GOLD Is the stock procurement procedure adhered to?
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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
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27.1.Has a review been conducted to determine performance measurement KPIs?
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27.2.Are the approved KPIs documented and distributed to all involved?
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27.3.Are the KPIs formally reported on?
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27.4.Is there a formal Root Cause Failure analysis process in place?
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27.5.Are chronic failures identified and addressed, i.e. is there a continuous improvement action plan in place?
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27.6.Is the equipment Availability measured and analysed (trended)?
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27.7. Is the Planned Vs Unplanned Work Ratio documened and reported?
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27.8. Is there a Backlog board in place?
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27.9. Is the backlog board updated daily?
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27.10. Is a weekly maintenance plan issued to the maintenance staff (supervisors & artisans) prior to the week commencing?
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27.11. GOLD Is the equipment MTTR measured and analysed (trended)?
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27.12. GOLD Is the equipment MTBF measured and analysed (trended)?
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27.13. GOLD Is the equipment Labour utilisation measured and analysed (trended)?
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27.14. GOLD Are top ten cost items identified and reported per machine type per month
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27.15. GOLD Is the root cause failure programme resulting in improved reliability and/or reduced costs.
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27.16. GOLD Are Planned versus Unplanned works ratios understood and proactively managed.
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27.17. GOLD Are top ten downtime items identified and reported per machine type per month
28. OPERATIONS - STANDARDS
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28.1.Have work place standards been documented?
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28.2.Have they been approved by the responsible manager?
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28.3.Have the standards been communicated to all applicable personnel?
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28.4.Are formal inspections conducted to measure compliance with the standards?
29. OPERATIONS - SURVEY
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29.1.Are survey plans available for all areas of development?
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29.2.Are special instructions noted on plans where applicable?
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29.3.Do all relevant departments approve plans prior to their final release?
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29.4.Are the survey plans issued to all necessary personnel?
30. OPERATIONS - KPIs
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30.1.Have Key performance indicators been determined and documented?
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30.2.Do all pieces of equipment been assigned KPIs?
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30.3.Have the KPIs been communicated to all personnel involved?
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30.4.Are KPIs measured and formally reported on?
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30.5. GOLD Is action taken when KPIs not to expectation?
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30.6. GOLD Do individuals receive feedback regarding their daily and monthly performance and any related deficiencies.
31. OPERATIONS - SYSTEM OVERVIEW
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31.1.Is there a system in place for conducting unbiased audits?
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31.2.Are previous Audit reports available?
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31.3.Have Action Plans been established, based on the findings of these Audits?
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31.4.Have the above action plans been approved and implemented?
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31.5. GOLD Is system performance tracked and trended on a monthly basis
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31.6. GOLD Is the system used as a tool for continuous improvement