Sample - Pre-Startup Safety Review

• Audit Title

• Client / Site

• Conducted on

  Date

• Prepared by

• Location
  Address

• Personnel

• New Equipment

• Modified Equipment

• Equipment Name

• Line/Location of Equipment

Inspection Team

• General Manager

• Plant Egineer

• Safety Manager

• Initiator

• Ops Manager

• Technical Services

• Machine Operator

• Maintenace Mechanic

• Environmental Manager

Lockout/Tagout

• Is the machine capable of being locked out?

  Yes

  No

  N/A

• Has the equipment specific lockout/tag out procedure been developed?

  Yes

  No

  N/A

• Are there any special lockout devices needed, if so have they been ordered and distributed to the appropriate personnel?

  Yes

  No

  N/A

• Have Sanitation, production, and maintenance employees been properly trained on the lockout procedures?

  Yes

  No

  N/A

• Have the FSIS IIC been briefed on the new pocedures?

  Yes

  No

  N/A

Mechanical Hazards

• Are equipment disconnects and operating controls labeled?

  Yes

  No

  N/A

• Are the start and stop controls within easy reach of the operator?

  Yes

  No

  N/A

• Is there a PM for the equipment? Are maintenace personnel trained to perform the PM?

  Yes

  No

  N/A

• Can the machine be oiled without removing the safeguards?

  Yes

  No

  N/A

• If there is more than one operator, are separate controls provided?

  Yes

  No

  N/A

• Are Emergency Stops accessible to the operator and working?

  Yes

  No

  N/A

Machine Guarding

• Have all pinch points and points of operation been properly guarded?

  Yes

  No

  N/A

• Have all chains and sprockets been properly guarded?

  Yes

  No

  N/A

• Are there any exposed set screws, key ways, collars, etc?

  Yes

  No

  N/A

• Have all pulleys and belts been properly guarded?

  Yes

  No

  N/A

• Have augers (if present) been properly guarded?

  Yes

  No

  N/A

• Are all machine guards securely attached?

  Yes

  No

  N/A

• Are interlocks prohibited from being bypassed if applicable?

  Yes

  No

  N/A

• Test all interlocks to ensure functioning properly if applicable?

  Yes

  No

  N/A

• Saw blades, is only the length necessary to cut product exposed?

  Yes

  No

  N/A

• Are all shafts ends covered with a non-rotating cap or cut down to a length of less than 1/2 the diameter of the shaft?

  Yes

  No

  N/A

Electrical

• Is the machine wired to NEC and NFPA code?

  Yes

  No

  N/A

• Is the machine grounded?

  Yes

  No

  N/A

• Is the power supply correctly fused and protected?

  Yes

  No

  N/A

• Will additions or modifications require an Arc Flash analysis?

  Yes

  No

  N/A

• Are all electrical connections secured, cords only the length necessary, conduit only used where required (no cords running through walls, under doors, etc)?

  Yes

  No

  N/A

• Is there any temporary equipment S/O cord -allowed for only 90 days- if any follow up required?

  Yes

  No

  N/A

Personal Protective Equipment

• Has PPE Hazard Analysis been conducted for new jobs?

  Yes

  No

  N/A

• Is required PPE available and issued to operators?

  Yes

  No

  N/A

• Have operators been properly trained in use and care of required PPE?

  Yes

  No

  N/A

Hearing

• Have appropriate measures been taken to safeguard workers against noise hazards?

  Yes

  No

  N/A

• Has an area survey been conducted?

  Yes

  No

  N/A

• If above 85 dB, has noise reduction measures been considered?

  Yes

  No

  N/A

Evacuation/Egress

• Have existing means of egress been obstructed or changed (at least 28")?

  Yes

  No

  N/A

• Have exit routes been rerouted if necessary?

  Yes

  No

  N/A

• Have employees been trained in new exit routes?

  Yes

  No

  N/A

• Has the emergency evacuation drawing been updated?

  Yes

  No

  N/A

• Is head room at least 7 feet high with no overhead obstructions below 6'8"?

  Yes

  No

  N/A

• Have all emergency exits been designated by appropriate signage/lighting?

  Yes

  No

  N/A

• Are new sprinkler systems operational and tested?

  Yes

  No

  N/A

• Fire Extinguisher accessible and adequately marked?

  Yes

  No

  N/A

Ventilation

• Does the new equipment generate hazardous vapors/gasses/fumes which will require additional ventilation?

  Yes

  No

  N/A

• If yes, has ventilation been installed?

  Yes

  No

  N/A

• If ventilation has not been installed, have employees been instructed in temporary hazard abatement procedures?

  Yes

  No

  N/A

Ergonomics

• Has an ergonomic audit (EJMS) been conducted of the new/modified equipment?

  Yes

  No

  N/A

• Have identified ergonomic hazards been corrected?

  Yes

  No

  N/A

Confined Spaces & Hazardous Locations

• Has the new equipment created a hazardous location?

  Yes

  No

  N/A

• What is the nature of the hazard?

  Flammable

  Toxic

  Extreme Temp

  Confined Space

• Are confined spaces, if any, permit required?

  Yes

  No

  N/A

• Are all hatches and other means of entry labeled as confined spaces?

  Yes

  No

  N/A

• If yes, have space specific entry procedures been developed?

  Yes

  No

  N/A

• If yes, have employees been trained on entry procedures?

  Yes

  No

  N/A

Fall Protection

• Will the new equipment create a situation in which employees must work more than 4' above the floor and outside of a standard guard rail?

  Yes

  No

  N/A

• Has appropriate fall protection equipment been provided to employees?

  Yes

  No

  N/A

• Have employees been trained in the use of required fall protection equipment?

  Yes

  No

  N/A

• Have any slip/trip/fall hazards been created?

  Yes

  No

  N/A

Hazard Communication

• Has the new equipment introduced any new hazardous chemicals into the facility?

  Yes

  No

  N/A

• Have employees been trained in the hazards and protective measures for the new chemical?

  Yes

  No

  N/A

Training

• Does the new/modified equipment require additional process training?

  Yes

  No

  N/A

• If yes, has the training been conducted?

  Yes

  No

  N/A

• Have new training requirements, if any, been forwarded to the Training Department?

  Yes

  No

  N/A

Food Safety / USDA

• Is the new equipment designed and manufactured to be easily cleaned?

  Yes

  No

  N/A

• Is there an SOP in place to break down the equipment for cleaning?

  Yes

  No

  N/A

• Has USDA been notified of the addition and the start up of the equipment?

  Yes

  No

  N/A

• Has the Cleaning Contractor been notified of the addition and the start up date of the equipment?

  Yes

  No

  N/A

Air Permits

• Has equipment received the necessary air permits?

  Yes

  No

  N/A

• Has the regulatory agency been notified of start up?

  Yes

  No

  N/A

• Has an SOP been modified or created to control the equipment per regulations?

  Yes

  No

  N/A

• Has an updated SOP been submitted to regulators for approval?

  Yes

  No

  N/A

• Does the facility have spare/redundant critical equipment to keep equipment running within compliance standards?

  Yes

  No

  N/A

Wastewater Compliance

• Has the equipment recieved the necessary waste water permits and/or notifications?

  Yes

  No

  N/A

• Has an SOP been modified/created to control the equipment to not impact Waste Water?is wastewater

  Yes

  No

  N/A

• Is wastewater treatment operations prepared to handle the impact of this process change?

  Yes

  No

  N/A

SPCC/Storm water

• Are secondary containment and/or storm water controls in place?

  Yes

  No

  N/A

• Has the SPCC and/or STW plan been updated, including site maps?

  Yes

  No

  N/A

• Has a "BMP" been created for this potential pollution source?

  Yes

  No

  N/A

ISO 14001

• Are the necessary "Operational Controls" established and documented in the EMS?

  Yes

  No

  N/A

• Have any new reporting requirements been added to the Environmental calendar?

  Yes

  No

  N/A

• Is the process change an Aspect or Significant Aspect?

  Yes

  No

  N/A

• Has the training schedule been updated to include the process change?

  Yes

  No

  N/A

Waste/Chemical Notification /Utilities

• Are the procedures in place to handle the waste (haz or non haz) from the process change?

  Yes

  No

  N/A

• Has notification to regulators occurred to address EPCRA requirements?

  Yes

  No

  N/A

• Are appropriate back flow connections installed to prevent contamination of potable water?

  Yes

  No

  N/A

• Are the appropriate mechanical and procedural systems installed to minimize energy/water usage?

  Yes

  No

  N/A

• Please list any other issues or concerns which may have arisen during the inspection of the equipment.

• Safety

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• Engineering

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• Production

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