Title Page

  • Site conducted

  • Conducted on

  • Prepared by

  • Location

Safety Audit Checklist

  • Date:

  • Auditor Name:

  • Signature:

Walking, Working Surfaces

Stairs and Stairways

  • Are handrails, stair rail systems, or guard rail systems on all stairways having four or more risers?

  • Are all stairways at least 22 inches wide?

  • Are risers on stair steps uniform in size, with no riser higher than 9.5 inches?

  • Are stair treads uniform in size, with tread depth no less than 9.5 inches?

  • Are steps slip-resistant?

  • Are stairway handrails located between 30 inches and 38 inches above the leading edge of stair treads?

  • Is the distance of stair rail systems above the leading edge of stair treads at least 30 inches (if installed before 10/1/20) or 42 inches (if installed after 10/1/20)?

  • Are stairway handrails capable of withstanding a load of 200 pounds, applied in any direction?

  • Where stairs or stairways exit directly into any area where vehicles may be operated, are adequate barriers and warnings provided to prevent employees from stepping into traffic?

  • Audit Area Notes:

General Conditions-Floors

  • Are all walking/working areas free of slipping/tripping /fall hazards?

  • Apertures or openings enclosed or covered?

  • Clean, orderly, and free of oil or grease hazards?

  • No standing water on floors?

  • Grates over floor drains?

  • Nonslip surfaces wherever possible?

  • Audit Area Notes:

Walkways

  • Aisles are clearly marked?

  • Aisles are unobstructed?

  • Corners unobstructed to offer clear view?

  • Sufficiently wide for material handling?

  • Audit Area Notes:

Floor and Wall Openings

  • Are floor openings guarded by a cover, a guardrail, or equivalent on all sides (except at stairways or ladder entrances)?

  • Are toeboards (minimum vertical 3.5” height) installed around the edges of permanent floor openings where persons may pass below the opening?

  • Are skylight screens able to withstand a load of at least 200 pounds?

  • Are grates or similar type covers over floor openings such as floor drains designed to allow unimpeded foot traffic or rolling equipment?

  • Are unused portions of service pits and pits not in use either covered or protected by guardrails or equivalent?

  • Are floor or wall openings in fire-resistant construction provided with doors or covers compatible with the fire rating of the structure and provided with a self-closing feature when appropriate?

  • Audit Area Notes:

Elevated Surfaces

  • Are signs posted, when appropriate, showing the elevated surface load capacity?

  • Are surfaces that are elevated more than 30 inches provided with standard guardrails?

  • Are all elevated surfaces beneath which people or machinery could be exposed to falling objects provided with toeboards (minimum 3.5” vertical height)?

  • Is a permanent means of access and egress provided to elevated storage and work surfaces?

  • Is required headroom provided where necessary?

  • Is material on elevated surfaces piled, stacked, or racked in a manner to prevent it from tipping, falling, collapsing, rolling, or spreading?

  • Where railings are installed is the top rail between 39-42 inches and a mid rail installed?

  • Audit Area Notes:

Fall Protection

  • All fall protection equipment is inspected before each use?

  • Records of annual inspections for all fall protection equipment

  • Signage in place to designate fall protection areas?

  • All walking/working surfaces protected by guardrails or fall protection requirements?

  • Audit Area Notes:

Loading Docks

  • Are dock boards or bridge plates used when transferring materials between docks and trucks?

  • If loading dock height is 48 inches or higher, are there fall protection measures in place?

  • If activities bring high traffic close to a hazard (e.g. an edge), are the floors marked or guards in place?

  • Has the dock area been periodically cleaned to remove accumulated debris?

  • If present, is emergency equipment blocked or damaged (e.g., fire extinguisher)?

  • Are dock plates and boards designed for the loads, and are lift trucks being used properly and in good repair?

  • Audit Area Notes:

LADDERS

  • All labels are legible on each ladder?

  • Safety feet in good operable condition?

  • Clean rungs, unpainted?

  • No splinters on wood ladders?

  • No metal or aluminum ladders in electrical areas?

  • If used above roof, 3-foot extension above roof level?

  • Danger tags available for defective ladders?

  • Ladders not in use are properly stored and secured?

  • All open ladders are protected by a self-closing gate?

  • Any unsafe practices observed?

  • Audit Area Notes:

Permit Required Confined Spaces & Confined Spaces

  • Are all confined spaces labeled?

  • Comprehensive list of all confined and permit required confined spaces in the facility?

  • Personal protective equipment listed for each space ?

  • Lockout and tagout procedures listed for each space?

  • Entry procedures clearly defined?

  • Rescue plan in place for each confined space?

  • Proper rescue equipment inventory for all confined spaces?

  • Audit Area Notes:

LIGHTING

  • Illumination level sufficient for work performed?

  • Emergency lighting adequate and operating?

  • Task lighting on close-vision jobs?

  • Emergency lighting of all exit routes?

  • Any unsafe practices observed?

  • Audit Area Notes :

VENTILATION

  • Adequate ventilation within the specific work area?

  • Hoods properly connected to exhaust system?

  • Hoods draw air away from people?

  • Clean-out ports for ducts provided?

  • Maintenance clean-out schedule observed and recorded?

  • Fans properly guarded?

  • Audit Area Notes

NOISE CONTROL

  • Engineering controls applied where feasible?

  • Engineering controls in operation?

  • Administrative controls applied where feasible?

  • Administrative controls and regulations observed?

  • Hearing protection provided where sound levels exceed standard?

  • Employees wearing approved hearing protection?

  • Employees wearing approved hearing protection properly inserted in the ear canal

  • Any unsafe practices observed?

  • Audit Area Notes :

PERSONAL PROTECTIVE EQUIPMENT

  • Gloves or palm guards properly chosen for each job?

  • Eye or face protection properly selected for each job?

  • Head protection properly selected for each job?

  • Foot protection properly selected for each job?

  • Apron or protective clothing properly selected for each job?

  • Respiratory protection properly selected if necessary, for the job?

  • Hearing protection selected for areas above noise standard?

  • Adequate emergency rescue equipment available

  • Signage in place for required PPE in each area?

  • Any unsafe work practices observed?

  • Audit Area Notes:

HAND and PORTABLE TOOLS AND EQUIPMENT

  • All tools electrically grounded?

  • Tools in good condition of connecting cords, tools, and air hoses?

  • Guards and safety fixtures safe and operable?

  • Correct load rating for work performed?

  • Constant pressure switches on power tools? Safety switches?

  • Employees properly trained in operation of equipment?

  • Electrical extension cords in good condition?

  • Any unsafe working practices observed?

  • Audit Area Notes

MACHINE TOOLS

  • Guarding of power transmission equipment?

  • Guarding of pinch points, in-running points, and points of operation?

  • Interlock guards in operation?

  • Eye and face shields for protection are available where needed?

  • Operating controls locked when not in use?

  • Emergency stop buttons readily accessible and operable?

  • Guards or deflect devices provided for chips/sparks from rotating equipment where appropriate?

  • Machine tool operators properly trained in operation of equipment?

  • Tools (i.e. drill press, lathe, etc) properly anchored to the floor?

  • Audit Area Notes :

Material Handling

Hoisting and Lifting Equipment

  • Load capacity identified clearly?

  • Upper and lower stop limit working effectively?

  • Wireless and/or wired pendants clearly marked and working effectively?

  • Full, unrestricted view for operators?

  • Web slings, wire rope, and/or chains and other devices in good condition and free of defects?

  • Record of periodic inspection exits for web slings, wire rope, and/or chains and other devices?

  • Operators properly trained in the use of the equipment? Training records?

  • Daily inspections are being completed?

  • Any unsafe work practices observed?

  • Audit Area Notes:

Powered Industrial Trucks

  • All operators trained and licensed and records are up to date?

  • Daily checklists are completed? Annual review documented?

  • Load capacity labeled?

  • Overhead guards in place and load backrest extension in place?

  • Travel areas have adequate signage and mirrors?

  • Operators are traveling with fork or load at the appropriate height?

  • Vehicle driven backward with awkward or bulky loads?

  • Operators moving slow down ramps?

  • Forks placed evenly across load?

  • Railroad tracks crossed diagonally where appropriate?

  • Pedestrians given the right of way?

  • Duckboards properly secured?

  • Trailer truck or boxcar floors checked for safety of load?

  • Key from industrial truck is removed when out of operation?

  • Any unsafe work practices observed?

  • Audit Area Notes:

RECEIVING AND IN-PLANT MATERIALS HANDLING

  • Dock boards available?

  • Trailer truck wheel chocks available in receiving/shipping areas?

  • Pallets and skids in good repair?

  • Special storage area for unused skids and pallets?

  • Procedure to set aside broken skids and pallets?

  • Paths, aisleways, and stairways clear of obstructions?

  • Proper drainage to prevent accumulation of water or solvents?

  • Any unsafe work practices observed?

  • Audit Area Notes:

Conveyors

  • Power transmission on the conveyor guarded?

  • Any confined areas pose a risk to workers?

  • Risk of electrocution?

  • Belts and/or Chains in good condition?

  • Are emergency stop devices in close proximity to the worker/task?

  • Are unguarded moving parts at least 8 ft. above the walking working surface?

  • Audit Area Notes:

POWER SYSTEMS - MECHANICAL

  • Proper guarding of any nip points, rotating collars, cams, chucks, couplings, clutches, shafts, flywheels, spindles, bolt ends, key ends?

  • Emergency stops fully operational?

  • Adequate arrangements for oiling and greasing?

  • Correct adjustment of work rest device on grinding wheels?

  • Vent hood in place and ventilation operational for grinding wheels?

  • Employees trained in correct grinding methods?

  • Grinding wheel surface not damaged or worn?

  • Any unsafe practices observed?

  • Audit Area Notes:

POWER SYSTEMS - ELECTRICAL

  • Electrical control panels clearly identified and secured?

  • Only certified electrical specialists to have access to panels?

  • Grounding tested?

  • Flexible extension cords fray-free and absence of splices?

  • Electrical specialists trained in the operation/maintenance of this equipment?

  • Is there an assured grounding program?

  • Extension cords not being used in place of permanent electrical supplies?

  • Audit Area Notes:

COMPRESSED GASES

  • Special storage area away from heat sources?

  • Stored upright and chained to prevent falling over?

  • Contents legibly marked and segregated by item?

  • Caps hand-tight?

  • Mechanics and tradespeople properly trained in operation of equipment?

  • Any unsafe work practices observed?

  • Audit Area Notes:

POTENTIALLY HAZARDOUS CHEMICALS

  • Up-to-date chemical inventory completed and available for review?

  • SDS available for all chemicals or federally listed hazardous chemicals?

  • Written plant hazard communication program prepared and available?

  • Employees trained in proper handling of each chemical?

  • Labels on all supplier drums and chemicals?

  • Labels on in-plant transfer containers?

  • Adequate storage cabinets provided with proper venting?

  • Proper absorbent materials on hand for spills?

  • Drums or tanks properly bonded and grounded?

  • Containers inspected for corrosion?

  • Any unsafe work practices observed?

  • Audit Area Notes:

MACHINE GUARDING

  • Guard or safety device at each point of operation?

  • Guard fully prevents operator from reaching around guard?

  • Guards are totally effective and unable to be bypassed?

  • Trained employees are the only persons authorized to remove guards?

  • Employee removing the guard is held responsible to replace guards after completing repairs?

  • START and STOP controls within easy reach of operator?

  • Operators can see entire operation?

  • Controls clearly labeled?

  • Two-hand trips on hand-fed power presses where appropriate?

  • Machinery can be oiled and greased without removing guards?

  • All controls, including foot controls, guarded against accidental start-up?

  • Emergency stop controls clearly identified and readily accessible?

  • Adjusting or oiling procedures of moving machinery followed?

  • No bypassing or removing guards?

  • No operating equipment at unsafe speed?

  • Lockout and tagout procedures implemented and posted on each machine?

  • Personal protective equipment is used?

  • Mechanics or adjusters properly trained?

  • Any unsafe work practices observed?

  • Audit Area Notes:

LOCKOUT, TAGOUT SYSTEMS

  • Positive lockout systems provided for all power equipment?

  • Written local policy signed by each person so trained?

  • Locks with individual keys given to each trained employee where appropriate?

  • Danger tags provided and available for each trained person?

  • Only authorized persons allowed to perform this procedure

  • Prominent tags indicate use of the lockout system

  • Lockout system will reduce power to zero energy state

  • Lock out tagout boxes contain all necessary equipment and are accessible?

  • Lockout/tagout instructions posted on all equipment or accessible?

  • Evidence of lockout and tag out periodic audits?

  • Audit Area Notes:

Mobile Elevated Work Platforms

  • Pre-use inspection checklist completed?

  • Inspection record-keeping adequate?

  • All operator training up to date?

  • Operators follow safe use practice (Warning lines, CAZ, spotter when needed, working distance from power lines, etc.)?

  • Operators use proper fall protection equipment?

  • Audit Area Notes:

EMPLOYEE WORK PRACTICES

  • Loose hair or employee clothing acceptable for the work area?

  • Employee overexertion or exposure to cold or heat?

  • Potential for repetitive-motion injury?

  • Sturdy shoes suitable for the work environment?

  • Housekeeping in the work areas being observed throughout the shift?

  • Any unsafe work practices observed?

  • Audit Area Notes:

FIRST AID and MEDICAL SERVICES

  • Adequate materials and equipment available?

  • First aid cabinets clean and stocked?

  • Clear instructions on contacting outside medical resources?

  • Provisions for transportation to outside medical services?

  • Trained first-aiders with recent recertification

  • Any unsafe work practices observed?

  • WASTE DISPOSAL

  • Special containers provided for different types of waste—oily rags, chemicals, scrap paper and corrugated, garbage, medical waste, bloodborne pathogens waste, etc.?

  • Food waste handled separately?

  • Where required, waste properly labeled?

  • Satisfactory external cartage and disposal arrangements?

  • Approved disposal arrangements for hazardous waste?

  • Audit Area Notes:

BLOODBORNE PATHOGENS

  • A BBP coordinator designated?

  • Written exposure control plan prepared?

  • Employee training program developed?

  • Information available on the types, use, location, removal and handling of personal protective equipment?

  • Emergency contact person designated?

  • Information available on post-exposure follow-up following an accident?

  • Training records retained?

  • Hand-washing facilities available?

  • Work practices reviewed to reduce exposures?

  • Disposable and reusable sharps placed in a puncture-resistant, leak-proof container with BIOHAZARD label?

  • Arrangements made to clean and launder non-disposable items?

  • Disposal containers available for disposable PPE?

  • Employees instructed in proper way to remove gloves to minimize contamination?

  • Bins, pails, cans and other receptacles intended for reuse decontaminated on a regular schedule

  • Audit Area Notes:

Emergency Equipment & Preparedness

  • Date of last fire drill?

  • Fire equipment of proper type and size

  • Fire equipment clearly marked?

  • Sprinkler heads have adequate clearance from stacked materials or equipment?

  • Master control valves for sprinklers locked open and easily accessible?

  • Exits clearly marked, accessible and not blocked?

  • Is emergency equipment (alarm pull boxes, eyewashes, fire extinguishers, first aid kits, etc

  • Eyewash station clean, working and correct water temperature (60-100 Deg. F 16-38 Deg. C)? Eyewash bottles NOT expired?

  • Proper signs and instructions at eye baths?

  • Regular fire drills held—date of most recent:

  • AED units functional in good working order?

  • Any unsafe work practices observed?

  • Audit Area Notes:

EXITS and EMERGENCY PREPAREDNESS

  • No locked or barred exits restricting escape?

  • Emergency exits adequately illuminated?

  • Exterior exit surfaces clear for prompt exit?

  • Flammable materials removed from exit areas?

  • Exterior exit doors open outward to flat surface?

  • Written and posted emergency evacuation plan with exit map for all areas?

  • Audit Area Notes:

BUILDING EXTERIOR

  • No defective overhanging cornices, parapets, gutters, or tiling?

  • No loose bricks on chimneys or stacks?

  • All signage in place and readable?

  • All exits clear, free of debris, snow and ice?

  • Audit Area Notes:

YARD and ROADS

  • No obstructions or broken surfaces on roads?

  • Good housekeeping in yard areas?

  • No uneven or broken sidewalk surfaces?

  • Appropriate traffic signs and markers?

  • Rail siding beds in good repair and free of obstruction?

  • Areas of dry grass kept in check so they aren't a safety hazard?

  • Audit Area Notes:

OFFICES

  • Floors have no slippery surfaces due to excessive polish or wax?

  • No holes or depressions in floors?

  • Rugs in hallways or offices are free from holes, tears?

  • Aisles free of obstructions, including electric cords and outlets?

  • Stairwells and exits properly lighted?

  • No unsafe ladders or trolleys?

  • General housekeeping is good?

  • No top-heavy filing cabinets (either by loading or drawer opening)?

  • Fire escape doors unlocked and unobstructed for exit?

  • Switch and cover plates in place?

  • No fire hazards from cigarette butts?

  • Safe storage of flammables?

  • Persons trained in requirements of Hazard Communication Standard?

  • Correct type and placement of fire extinguishers?

  • First-aid facilities available?

  • Electric fans properly guarded?

  • Adequate ventilation?

  • Any unsafe work practices observed?

  • Evacuation routes posted?

  • Audit Area Notes:

EMPLOYEE TRAINING

  • New employee basic safety orientation being completed?

  • New employees trained in safe work practices of their jobs?

  • Transferred employees trained in the safe work practices of their jobs?

  • Checklist completion on safety orientation of new and transferred employees?

  • All training documents filed by employee for ease of access?

  • Any unsafe work practices observed?

  • Audit Area Notes:

PROCESS SAFETY MANAGEMENT

  • Chemicals used in the process and their maximum inventory listed?

  • SDS readily available on all chemicals?

  • Operating practices reviewed, consistent with known hazards of the chemicals in the process

  • Goals for training sessions detailed in writing in clear terms?

  • Training sessions documented?

  • Screening process developed to hire safe-operating contractors?

  • Contractor and personnel advised of known hazards at facility?

  • Emergency action plan reviewed with contractor personnel?

  • Hazards involved in nonroutine work communicated to operators and to maintenance personnel?

  • Work authorization permit system in effect outlining approvals required to do the job?

  • Management policy prepared and communicated that all incidents will be formally investigated?

  • Written instructions and training developed for emergency evacuation plans?

  • Disabled employees identified; they will receive assistance to evacuate to a safe zone?

  • Facility emergency control center established in a safe zone at the facility?

  • Compliance with the OSHA standard audited by a trained team?

  • Audit Area Notes:

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