Site Assessment - Manufacturing

• Site conducted

  Select

• Conducted on

  Date

• Prepared by

Positive Findings

• Note item that you find and like while assessing the facility

  Select Good Job Good Job Share with other facilites

  • Good Job
  • Good Job Share with other facilites

• Note item that you find and like while assessing the facility

  Select Good Job Good Job Share with other facilites

  • Good Job
  • Good Job Share with other facilites

• Note item that you find and like while assessing the facility

  Select Good Job Good Job Share with other facilites

  • Good Job
  • Good Job Share with other facilites

• Note item that you find and like while assessing the facility

  Select Good Job Good Job Share with other facilites

  • Good Job
  • Good Job Share with other facilites

• Note item that you find and like while assessing the facility

  Select Good Job Good Job Share with other facilites

  • Good Job
  • Good Job Share with other facilites

Training and Engagement

• Is the site up to date on their monthly safety training?

  Yes

  No

  N/A

  Question

• How is the training conducted ? classroom vs. individual online

  Classroom

  Individual

• Who is responsible for conducting the training?

• when do you conduct your weekly shop talks? (day of the week and time)

• How are your shop talks conducted?

• Does your site have an active safety committee?

  Yes

  No

  N/A

  Question

• What is your plan to address this?

• ask to see the notes from the most recent meeting

  Media

Incident and Near Miss Management

• Does the site have a near miss program?

  Yes

  No

  N/A

  Question

• Do the supervisors know where to find the documentation to update their incident packs?

  Yes

  No

  N/A

  Question

• Does the shop have incident packs accessible for the leads/SME's

  Yes

  No

  N/A

  Question

JHA

• Does the site have JHA's in place?

  Yes

  No

  N/A

  Question

• Are the JHA's being reviewed and updated Annually?

  Yes

  No

  N/A

  Question

• Are you reviewing and updating the JHA's after incidents and significant near misses

  Yes

  No

  N/A

  Question

• When was the last one updated?

Concerns

General Managers and Supervisors

• Ask the General Manager what safety concerns do you have regarding your site ? What keeps you up at night about your job

• Ask the Department Supervisor what safety concerns do you have regarding your departmen/shop ? What keeps you up at night about your job

Employees

• Ask the employee what concerns you about your job ? What keeps you up at night about your job

• Ask the employee what concerns you about your job ? What keeps you up at night about your job

• Ask the employee what concerns you about your job ? What keeps you up at night about your job

Safety Team Concerns

• Are there any concerns that you have at the site that are not a part of the assessment

  Yes

  No

  N/A

  Question

• Are there any concerns that you have at the site that are not a part of the assessment

  Yes

  No

  N/A

  Question

• Are there any concerns that you have at the site that are not a part of the assessment

  Yes

  No

  N/A

  Question

• Are there any concerns that you have at the site that are not a part of the assessment

  Yes

  No

  N/A

  Question

House Keeping

• Are slippery conditions eliminated in designated walkways and working surfaces?

  Yes

  No

  N/A

  Question

• Is the a mechanism in place to address any slippery conditions ie oil dry

  Yes

  No

  N/A

  Question

• <br>Are obstructions, such as nails, pallets, holes, tools, materials, equipment, or lose boards eliminated from walkways and working surfaces to allow for adequate passage?

  Yes

  No

  N/A

  Question

• Are passageways, walkways, and working surfaces kept clear of steel shot or similar abrasives that may create a slipping hazard?

  Yes

  No

  N/A

  Question

• Are aisles and passageways marked and kept clear?

  Yes

  No

  N/A

  Question

• ask the employee to walk you through how people navigate when walking through those areas

• Are hoses and electrical service cords positioned to prevent injury to workers or damage to the hoses and cords themselves (e.g., crossover planks, beneath grating, stowed overhead)?

  Yes

  No

  N/A

  Question

• <br>Are doorways, emergency exits, fire protection equipment, electrical panels, eyewash stations, and safety showers free from obstructions?

  Yes

  No

  N/A

  Question

• Is adequate lighting provided in work areas?

  Yes

  No

  N/A

  Question

• <br>Are exit routes clearly marked “Exit,” as well as indicating the direction of travel to the exit, if not immediately apparent?

  Yes

  No

  N/A

  Question

• Are exits markings and lighting adequate and appropriate?

  Yes

  No

  N/A

  Question

General Environmental Cotnrols (Sanitation)

• Are waste containers emptied regularly?

  Yes

  No

  N/A

  Question

• Have areas where water drains exist been cleared of debris ?

  Yes

  No

  N/A

  Question

• When was the last time they were cleaned?

Vermin Control

• Is there a vermin control program in place that is maintained?

  Yes

  No

  N/A

  Question

• Is the area free of rodents, insects, and vermin?

  Yes

  No

  N/A

  Question

• Note areas where you see or see evidence of vermin

Fire Protection and Prevention

• Are portable fire extinguishers provided, mounted, located and identified so that they are readily accessible to employees?

  Yes

  No

  N/A

  Question

• Do you have a third party come in and check your fire extinguishers annually ?

  Yes

  No

  N/A

  Question

• Are annual maintenance checks of portable fire extinguishers completed and records maintained of the date completed?

  Yes

  No

  N/A

  Question

• Note the response and follow up with recommendations

• Are portable fire extinguishers visually inspected each month?

  Yes

  No

  N/A

  Question

• find out who is responsible fore inspecting monthly and note below

• Are sprinkler systems inspected annually to assure that the system is maintained in good operating condition? (note ask IT if the server room has been checked )

  Yes

  No

  N/A

  Question

• if in Illinois the distance is 15 ft from the entrance. In TN the distance is 125ft In Indiana the distance is 8ft

• Are approved smoking areas the proper distance from common entrances ?

  Yes

  No

  N/A

  Question

• Is there any evidence of smoking in the shop or while operating power equipment ?

  Yes

  No

  N/A

  Question

Eyewash station inspection

• are eye wash facilities and quick drench showers available within the worksites where employees are exposed to dangerous corrosive materials

  Yes

  No

  N/A

  Question

• Is the area around the station clear of obstructions

  Yes

  No

  N/A

  Question

• are there any leaks

  Yes

  No

  N/A

  Question

• is the water clear?

  Yes

  No

  N/A

  Question

• Where plumed stations are used are they checked weekly?

  Yes

  No

  N/A

  Question

• who checks them?

  Yes

  No

  N/A

  Question

Personal Protective Equipment

• Are affected employees using appropriate eye or face protection while performing their job duties (exposed to eye or face hazards from flying particles, molten metal, liquid chemicals, acids or caustic liquids, chemical gases or vapors, or potentially injurious light radiation?)

  Yes

  No

  N/A

  Question

• What is the site steel toe shoe policy

Fall Protection

• is there ever a time where an employee needs to use a full body harness?

  Yes

  No

  N/A

  Question

• Does the employee have their own harness?

  Yes

  No

  N/A

  Question

• Is the harness in good condition?

  Yes

  No

  N/A

  Question

• How may do you have on hand

  Media

• What type of lanyard do you use (retractable vs Bungee)

  Yes

  No

  N/A

  Question

Hand Protection

• Are gloves used in the facility

  Yes

  No

  N/A

  Question

• What Type and where

  Media

• Is the hand protection in use the appropriate for the job?

  Yes

  No

  N/A

  Question

• Are the gloves being used in good repair i.e. free from holes cracks and other damage

  Yes

  No

  N/A

  Question

Hearing

• Is hearing protection required in this facility?

  Yes

  No

  N/A

  Question

• Why not ?

• Where must hearing protection be worn?

Head Protection

• NOTE: this question applies when working with the travel lift and/or during crane testing

• Are there instances where head protection is in use/required

  Yes

  No

  N/A

  Question

• In what instances are hard hat used?

• Are your Hard Hat's current - 5 years from date listed

  Yes

  No

  N/A

  Question

Respirators and Weld hoods

• Are the respirators stored in a way that will protect them from contamination, heat, extreme temperatures and other damage?

  Yes

  No

  N/A

  Question

• Do you have any instances where personnel are share respirators

  Yes

  No

  N/A

  Question

Hand and Power tools

• Are all portable power tools properly grounded?

  Yes

  No

  N/A

  Question

• confirm if the equipment has an internal grounding mechanism (double insulation) with manager/supervisor/lead/SME

  Yes

  No

  N/A

  Question

• Do air nozzles meet OSHA requirements ? emit not more than 30 psi has nozzel pressure reducing mechanisim.

  Yes

  No

  N/A

  Question

• Are portable power tools equipped with appropriate guards where applicable ? rotating parts, pinch pints must be guarded

  Yes

  No

  N/A

  Question

• Are portable grinders completely and adequately guarded?

  Yes

  No

  N/A

  Question

Bench Grinders

• Are bench grinders set to the required width (no more than an 1/8" of space from the tounge)

  Yes

  No

  N/A

  Question

• Are bench grinders properly guarded?

  Yes

  No

  N/A

  Question

Hazardous Materials

• Are fire control devices located in areas where flammable liquids are stored or used?

  Yes

  No

  N/A

  Question

• Are flammable and combustible liquids stored properly ?

  Yes

  No

  N/A

  Question

• Are power shut-off controls for fuel pumps remotely located, clearly identified, and readily accessible?

  Yes

  No

  N/A

  Question

• Are all secondary chemical containers properly labeled? (add document that shows what properly is)

  Yes

  No

  N/A

  Question

• Are signs posted to prohibit smoking in fueling areas or where flammable or combustible liquids are received, dispensed, or stored?

  Yes

  No

  N/A

  Question

• Are “No Smoking” signs conspicuously posted at all paint spraying areas and paint storage rooms?

  Yes

  No

  N/A

  Question

Compressed gas cylinders

• Are all compressed gas cylinders legibly marked to indicate their contents?

  Yes

  No

  N/A

  Question

• Are cylinders stored in upright position and immobilized by chains or other means to prevent them from falling to prevent damage and tampering?

  Yes

  No

  N/A

  Question

• ask various employees what their process is and the equipment they use to move them.

• How do you move the compressed gas cylinders from one location to the next

• Are oxygen and acetylene stored separately (20 ft distance)

Welding Cutting Brazing

• Do we ever reuse drums, barrels, tanks, or other containers that contained flammable materials, or materials that may produce flammable or toxic vapors when heated?

  Yes

  No

  N/A

  Question

• Do we do any type of work that would require us to weld in a confined space ? (provide example)

  Yes

  No

  N/A

  Question

• In what instances are we doing this type of work?

  Yes

  No

  N/A

  Question

• Are confined spaces adequately ventilated to prevent the accumulation of toxic materials or oxygen deficiencies during welding or cutting operations?

  Yes

  No

  N/A

  Question

• Have all fire hazards in the vicinity of welding or cutting been removed or guarded? (trash, paper, carboard)

  Yes

  No

  N/A

  Question

• Are the welder and any helpers or attendants using properly selected helmets, goggles, or face shields during any welding, cutting, or brazing operation?

  Yes

  No

  N/A

  Question

• Ask the employee who weld/cut/braze where is the closest first aid cabinet ?

• What kind of ventilation is provided in welding or cutting areas?

• Ask the employee: when Welding what do you ground to?

• Are the lead cables for electrical arc welding units free from splices or open insulation ?

  Yes

  No

  N/A

  Question

Electrical

• Are electrical cords, outlets and plugs in good condition ?

  Yes

  No

  N/A

  Question

• Are there any areas where extension cords are being used as a permanent wiring solution ?

  Yes

  No

  N/A

  Question

• What is the plan to eliminate the extension cord use

  Yes

  No

  N/A

  Question

• Are there any areas where 3 way plugs are being used as a power source for equipment ?

  Yes

  No

  N/A

  Question

• Are all pull boxes, junction boxes, and fittings provided with covers are in good condition?

  Yes

  No

  N/A

  Question

• Do all electrical panels and power distribution cabinets have a minimum of 3 feet of clear space in front of them?

  Yes

  No

  N/A

  Question

• Are electrical outlet, cords, etc. in or near wet areas an approved type for the environment? (ie. GFI)

  Yes

  No

  N/A

  Question

• Are all electrical circuit controls, breakers, fuses and disconnects marked to show what they control?

  Yes

  No

  N/A

  Question

Lifting Devices

Cranes (overhead, jibs, etc)

• Are Daily Crane checklist completed ?

  Yes

  No

  N/A

  Question

• What do you do with the check lists when completed?

  Drawing

• If there is an issue found what happens next?

• what are go no go findings that require a shut down of the crane?

• Are the control pendants properly marked?

  Yes

  No

  N/A

  Question

• Do you have an outside vendor inspect your cranes annually

  Yes

  No

  N/A

  Question

Hoists, Hooks, Slings and Chain Lifts

• Are Strong backs visibly marked with load rating ?

  Yes

  No

  N/A

  Question

• Are all hoists and chain lifts visibly marked for maximum load capacity?

  Yes

  No

  N/A

  Question

• Are chains, slings and wire ropes for hoists in good condition free from any visible damage?

  Yes

  No

  N/A

  Question

• Are annual inspection done on your slings and chains ?

  Yes

  No

  N/A

  Question

• Is your rubber tire gantry crane visibly marked with Load rating

  Yes

  No

  N/A

  Question

• Do hoist hooks on come-alongs have safety latches in working order?

  Yes

  No

  N/A

  Question

Magnets

• Are all magnets in good working order ?

  Yes

  No

  N/A

  Question

• Is there any type of inspection/PM program for the magnets

  Yes

  No

  N/A

  Question

• who is responsible for the inspection/PM?

• How often is it completed?

  Yes

  No

  N/A

  Question

• Who is responsible for the PM program?

  Yes

  No

  N/A

  Question

• Yes

  No

  N/A

  Question

Powered Industrial Vehicles

• Have the daily VCR's been completed on all powered industrial vehicles (forklifts, aerial lifts, scissor lift etc)

  Yes

  No

  N/A

  Question

• If there is an issue with the forklift who does it get reported to and what are the next step

• When are the VCR's are filled out

• Who gets the completed check lists

• Where and how long are the kept

• what are the go/no go sections of the check list

• Are the Powered equipement drivers operating in a safe manner

  Yes

  No

  N/A

  Question

• Is there a document that provides a listing of approved operators with the anniversary date of their required evaluation / training?

  Yes

  No

  N/A

  Question

• When aerial and scissor lifts are in use is the area below marked off to prevent pedestrians from walking underneath it.

  Yes

  No

  N/A

  Question

Machine Guarding

• Are there any pieces of equipment that require some type of guard ?

  Yes

  No

  N/A

  Question

• do the pieces of equipment have point of operation guarding in place where needed?

  Yes

  No

  N/A

  Question

• Note the name and location of the equipment

  Yes

  No

  N/A

  Question

• Do all pieces of equipment have point of operation guarding in place?

  Yes

  No

  N/A

  Question

• Do saws, drill presses, or other fixed equipment have means provided to secure them in place, or are secured to a portable table?

  Yes

  No

  N/A

  Question

Paint Department Specific

• Does the site have Paint operations

  Yes

  No

  N/A

  Question

• Do all electrical wiring and equipment located in or near paint kitchen areas comply with National Electrical Code provisions for hazardous locations?

  Yes

  No

  N/A

  Question

• Is there any evidence of painting outside of the paint booth

  Yes

  No

  N/A

  Question

• ask the department manager/supervisor why this is occurring and how it is managed

• Are there any 55 gallon drums containing flammable liquids sitting outside of the paint booth/kitchen?

  Yes

  No

  N/A

  Question

• When were drums received ?

• 1910.106(e)(2) "Incidental storage or use of flammable liquids" 1910.106(e)(2)(ii)(b) The quantity of liquid that may be located outside of an inside storage room or storage cabinet in a building or in any one fire area of a building shall not exceed: 25 gallons of Call IA liquids in containers, 120 gallons of Class IB, IC or II or III liquids in containers , 660 gallons of class IB, IC, II or III liquids in a singe portable tank.

• What is the shops process to clean spray nozzles

• When do you change the paint booth filters? What is the mechanism you use to identify the change needs to occur?

• How do you identify if the gages on the paint booth/blast bay are working? i.e. is there a PM system or is there a 3rd party vendor.

• Has the supplied air to the paint booth and blast bay been tested?

  Yes

  No

  N/A

  Question

• how often is it tested

  Yes

  No

  N/A

  Question

• Can employees working in the paint and blast booths hear the emergency evacuation notifications.

  Yes

  No

  N/A

  Question

• What is the process used to clean the paint shop floor?

• Does the paint booth have a visible gauge/manometer, audible alarm or pressure activated device?

  Yes

  No

  N/A

  Question

• please note: 29 CFR 1910.107(g)(2):Cleaning. All spraying areas shall be kept as free from the accumulation of deposits of combustible residues as practical, with cleaning conducted daily if necessary. Scrapers, spuds, or other such tools used for cleaning purposes shall be of non-sparking material.

• Where breathing air is supplied to respirators used by paint team is there evidence (i.e. tags) of routine maintenance/checks on the compressors?

  Yes

  No

  N/A

  Question

Confined Space

• Has the shop identified any permit and/or non permit required confined spaces

  Yes

  No

  N/A

  Question

• Are the confined spaces labeled

  Yes

  No

  N/A

  Question

• Does the site have a written confined space program

  Yes

  No

  N/A

  Question

• Have affected employees been trained on the confined space program

  Yes

  No

  N/A

  Question

Material handling and Storage

• Are the storage racks secured to the ground?

  Yes

  No

  N/A

  Question

• Are items stored on the top of the rack secured to prevent falling

  Yes

  No

  N/A

  Question

• Are materials stacked in a manner where they are stable when stored in Racks, on the floor and/or on the equipment while moving?

  Yes

  No

  N/A

  Question

• Is good housekeeping maintained in storage areas?

  Yes

  No

  N/A

  Question

• Are load limit weights posted in the storage areas/racks?

  Yes

  No

  N/A

  Question

• Are the racks standing plumb and level?

  Yes

  No

  N/A

  Question

• Are components rusted or corroded?

  Yes

  No

  N/A

  Question

• Is the rack showing signs of being overloaded?

  Yes

  No

  N/A

  Question

• Are the uprights bent or damaged?

  Yes

  No

  N/A

  Question

• Are there pallet stops or guards in place where there is a single storage rack adjacent to service aisles?

  Yes

  No

  N/A

  Question

• Is there overhead guarding at tunnel bays?

  Yes

  No

  N/A

  Question

• Are the beams seated tightly into the uprights?

  Yes

  No

  N/A

  Question

• Are there any dents, distortions or evidence of an impact?

  Yes

  No

  N/A

  Question

• are there any pallets over-hanging, double stacked, or damaged in the racks?

  Yes

  No

  N/A

  Question

• Are the pallets the correct size for the rack?

  Yes

  No

  N/A

  Question

Docks

• Is the dock well-lit or are there working dock lights at each bay?

  Yes

  No

  N/A

  Question

• Is the dock area clear of debris, spills, oil , rain/ice ?

  Yes

  No

  N/A

  Question

• Are there fire extinguishers available?

  Yes

  No

  N/A

  Question

• Are the docks closed and/or locked when not in use ?

  Yes

  No

  N/A

  Question

• Are dock barriers in use?

  Yes

  No

  N/A

  Question

• What is the proceudure for unloading /loading a trailer?

• Are chocks or dock locks used?

  Yes

  No

  N/A

  Question

• are chocks/dock locks in good condition?

  Yes

  No

  N/A

  Question