Information

  • Site conducted

  • Document No.

  • Audit Title

  • Client / Site

  • Conducted on

  • Prepared by

  • Location
  • Personnel

Machinery

  • Does this Department/Area have machinery that requires human interface?

  • Machines and mechanical equipment and adjacent areas kept clear of tools, scrap, trash, etc?

  • Are all machines and mechanical equipment anchored to prevent moving?

  • OSHA 1910.212(b)- Anchoring fixed machinery. Machines designed for a fixed location shall be securely anchored to prevent walking or moving.

  • Each machine equipped with emergency stop readily accessible and identified to operator?

  • OSHA 1910.144(a)(1)(iii)- Stop. Emergency stop bars on hazardous machines such as rubber mills, wire blocks, flat work ironers, etc., shall be red. Stop buttons or electrical switches which letters or other markings appear, used for emergency stopping of machinery shall be red.

  • Each machine equipped with electrical disconnect with lock-out means?

  • Lock-out procedure provided and enforced?

  • All rotating, reciprocating or otherwise moving parts less than 8 feet from floor or working surface enclosed in guard?

  • Appropriate and properly designed guards provided to protect personnel from flying chips, particles, sparks, water, lubricants, etc?

  • OSHA 1910.212(a)(1)- Types of guarding. One or more methods of machine guarding shall be provided to protect the operator and other employees in the machine area from hazards such as those created by point of operation, ingoing nip points, rotating parts, flying chips and sparks. Examples of guarding methods are-barrier guards, two-hand tripping devices,electronic safety devices, etc.

  • Power transmission components (belts, pulleys, chains/sprockets, couplings, etc. less than 7 feet from floor or working/walking surface enclosed in properly designed/fabricated guard?

  • OSHA 1910.219(b)(1)- Flywheels. Flywheels located so that any part is seven (7) feet or less above floor or platform shall be guarded in accordance with the requirements of this subparagraph:

    OSHA 1910.219(b)(1)(i)- With an enclosure of sheet, perforated, or expanded metal, or woven wire;

  • Point-of-operation guards provided on shears, saws, presses, machines having in-running nip-points, etc?

Emergency Response & Fire Protection

  • Portable fire extinguishers provided in adequate number and type; maximum travel distance for all units not in excess of 75 ft. (50 ft. in hazardous areas)?

  • OSHA 1910.157(d)(2)- The employer shall distribute portable fire extinguishers for use by employees on Class A fires so that the travel distance for employees to any extinguisher is 75 feet (22.9 m) or less.

    OSHA 1910.157(d)(4)- The employer shall distribute portable fire extinguishers for use by employees on Class B fires so that the travel distance from the Class B hazard area to any extinguisher is 50 feet (15.2 m) or less.

  • Fire extinguishers inspected not less than monthly for general condition and operability and noted on inspection tag attached to the extinguisher?

  • OSHA 1910.157(c)(4)- The employer shall assure that portable fire extinguishers are maintained in a fully charged and operable condition and kept in their designated places at all times except during use.

  • Fire extinguishers mounted in readily accessible locations; access to extinguishers clear and obstructed?

  • OSHA 1910.157(c)(1)- The employer shall provide portable fire extinguishers and shall mount, locate and identify them so that they are readily accessible to employees without subjecting the employees to possible injury.

  • Are all fire extinguisher locations clearly marked or identified?

  • OSHA 1910.157(c)(1)- The employer shall provide portable fire extinguishers and shall mount, locate and identify them so that they are readily accessible to employees without subjecting the employees to possible injury.

  • Are all fire extinguishers have a minimum of a 3 foot clearance?

  • >40lb extinguishers mounted no more than 5 feet above the floor. <40lb extinguishers mounted no more than 3.5 feet above the floor. In all cases they are mounted at least 4 inches above the floor?

  • OSHA 1910.157(c)(1)- The employer shall provide portable fire extinguishers and shall mount, locate and identify them so that they are readily accessible to employees without subjecting the employees to possible injury.

  • Flammable or combustible liquids stored in metal “safety” containers away from heat, sources of ignition?

  • Flammable/combustible liquids stored in production areas limited to quantity needed for one eight-hour shift?

  • Bulk storage of flammable liquids located minimum of 50 feet from other buildings, facilities, or production areas, and in suitable fire-safe buildings or enclosures?

  • Pallets stored 50+ feet away from any building?

  • Wash Tanks/Parts Washers using flammable solvents equipped with self-closing covers?

  • All eye wash stations tagged and dated as working properly?

  • Emergency lighting provided in area as needed?

  • OSHA 1910.37(b)(1)- Each exit route must be adequately lighted so that an employee with normal vision can see along the exit route.

  • Emergency procedures conspicuously displayed for employees?

Aisles, Exits, Doorways & Stairs

  • Are exit aisles clearly marked, accessible, visible and unobstructed ?

  • OSHA 1910.37(a)(3)- Exit routes must be free and unobstructed. No materials or equipment may be placed, either permanently or temporarily, within the exit route. The exit access must not go through a room that can be locked, such as a bathroom, to reach an exit or exit discharge, nor may it lead into a dead-end corridor. Stairs or a ramp must be provided where the exit route is not substantially level.

  • Are all exit doors clearly marked and accessible from both sides?

  • OSHA 1910.37(b)(2)- Each exit must be clearly visible and marked by a sign reading "Exit."

    OSHA 1910.37(b)(5)- Each doorway or passage along an exit access that could be mistaken for an exit must be marked "Not an Exit" or similar designation, or be identified by a sign indicating its actual use (e.g., closet).

    OSHA 1910.37(b)(3)- Each exit route door must be free of decorations or signs that obscure the visibility of the exit route door.

  • All doors operate smoothly with little effort to operate?

  • OSHA 1910.36(d)(1)- Employees must be able to open an exit route door from the inside at all times without keys, tools, or special knowledge. A device such as a panic bar that locks only from the outside is permitted on exit discharge doors.

  • Are stairways clear, handrails and/or guard rails provided, treads and risers in good repair with non-slip surfaces and adequate lighting?

  • Are stairways provided with standard handrails (30-34” high) and mid-rails for every flight having four (4) or more risers?

  • Are all open sided floors, platforms and runways four (4’) feet or more above floor or ground level provided with standard guard rail, mid rail and toeboards?

  • Are ladder access points and other openings in guardrails protected with securely attached chain or other barriers?

Electrical Cords & Equipment

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  • Are all switches mounted in clean, tightly closed metal boxes?

  • Are outlet conditions and plugs in good working order?

  • OSHA 1910.303(b)(1)- Examination. Electric equipment shall be free from recognized hazards that are likely to cause death or serious physical harm to employees.

  • Are all extension cords inspected for proper grounding? 3rd. post present?

  • 1910.334(a)(2)(i)
    Portable cord and plug connected equipment and flexible cord sets (extension cords) shall be visually inspected before use on any shift for external defects (such as loose parts, deformed and missing pins, or damage to outer jacket or insulation) and for evidence of possible internal damage (such as pinched or crushed outer jacket). Cord and plug connected equipment and flexible cord sets (extension cords) which remain connected once they are put in place and are not exposed to damage need not be visually inspected until they are relocated.

  • Are all unused openings (including conduit knockouts) enclosed?

  • OSHA 1910.303(b)(7)(i)- Unused openings in boxes, raceways, auxiliary gutters, cabinets, equipment cases, or housings shall be effectively closed to afford protection substantially equivalent to the wall of the equipment.

  • Are all switches and disconnects clearly marked to show their purpose and/or equipment controlled?

  • OSHA 1910.303(f)(2)- Services, feeders, and branch circuits. Each service, feeder, and branch circuit, at its disconnecting means or overcurrent device, shall be legibly marked to indicate its purpose, unless located and arranged so the purpose is evident.

  • Are all fuse boxes labeled properly, doors closed and secured?

  • OSHA 1910.303(f)(2)- Services, feeders, and branch circuits. Each service, feeder, and branch circuit, at its disconnecting means or overcurrent device, shall be legibly marked to indicate its purpose, unless located and arranged so the purpose is evident.

  • Is there any evidence of overheating on switches, connections, disconnect, etc.?

  • No temporary wiring to permanently located or fixed equipment?

  • OSHA 1910.305(g)(1)(iv)- Unless specifically permitted otherwise in paragraph (g)(1)(ii) of this section, flexible cords and cables may not be used:
    OSHA 1910.305(g)(1)(iv)(A)-As a substitute for the fixed wiring of a structure;
    OSHA 1910.305(g)(1)(iv)(B)-Where run through holes in walls, ceilings, or floors;
    OSHA 1910.305(g)(1)(iv)(C)- Where run through doorways, windows, or similar openings;
    OSHA 1910.305(g)(1)(iv)(D)- Where attached to building surfaces;
    OSHA 1910.305(g)(1)(iv)(E)- Where concealed behind building walls, ceilings, or floors; or
    OSHA 1910.305(g)(1)(iv)(F)- Where installed in raceways, except as otherwise permitted in this subpart.

  • Are all plugs outside or within 6' of a water source equipped with a GFCI or breaker GFCI?

  • Are all power cords kept clear of traffic, walking/working surfaces?

  • No evidence of fraying or strain damage on any electrical power/service cords?

  • OSHA 1910.305(g)(2)(iii)- Flexible cords and cables shall be connected to devices and fittings so that strain relief is provided that will prevent pull from being directly transmitted to joints or terminal screws.

  • Are all outdoor receptacles properly covered by weatherproof cover?

  • OSHA 1910.305(j)(2)(iv)- A receptacle installed in a wet or damp location shall be suitable for the location.

    OSHA 1910.305(j)(2)(v)- A receptacle installed outdoors in a location protected from the weather or in other damp locations shall have an enclosure for the receptacle that is weatherproof when the receptacle is covered (attachment plug cap not inserted and receptacle covers closed).

    Note to paragraph (j)(2)(v) of this section. A receptacle is considered to be in a location protected from the weather when it is located under roofed open porches, canopies, marquees, or the like and where it will not be subjected to a beating rain or water runoff.

  • Are electrical substations, switch-rooms, motor rooms kept locked, access limited to authorized personnel?

Material Handling & Load Bearing Devices

Material Handling & Load Bearing Devices

  • Does this Department/Area use forklifts to move material?

  • Spot check forklift or other mobile equipment for pre-shift inspection. Was pre-shift inspection completed?

  • OSHA 1910.178(q)(7)- Industrial trucks shall be examined before being placed in service, and shall not be placed in service if the examination shows any condition adversely affecting the safety of the vehicle. Such examination shall be made at least daily. Where industrial trucks are used on a round-the-clock basis, they shall be examined after each shift. Defects when found shall be immediately reported and corrected.

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  • Spot check forklift or other mobile equipment for pre-shift inspection. Was pre-shift inspection completed?

  • OSHA 1910.178(q)(7)- Industrial trucks shall be examined before being placed in service, and shall not be placed in service if the examination shows any condition adversely affecting the safety of the vehicle. Such examination shall be made at least daily. Where industrial trucks are used on a round-the-clock basis, they shall be examined after each shift. Defects when found shall be immediately reported and corrected.

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  • Does this Department/Area use cranes and/or slings to move material?

  • Are nylon or other lifting slings in good condition, no evidence of mechanical damage, broken/separated strands or other visible defects?

  • OSHA 1910.184(d)- Inspections. Each day before being used, the sling and all fastenings and attachments shall be inspected for damage or defects by a competent person designated by the employer. Additional inspections shall be performed during sling use, where service conditions warrant. Damaged or defective slings shall be immediately removed from service.

  • Are all lifting devices tagged and stored properly with no unauthorized devices?

  • OSHA 1910.184(c)(14)- Employers must not use slings without affixed and legible identification markings.

    OSHA 1910.184(e)(1)- Sling identification. Alloy steel chain slings shall have permanently affixed durable identification stating size, grade, rated capacity, and reach.

  • Are damaged or defective slings immediately removed from service?

  • OSHA 1910.184(c)(1)- Slings that are damaged or defective shall not be used.

    OSHA 1910.184(e)(7)(i)- Worn or damaged alloy steel chain slings or attachments shall not be used until repaired. When welding or heat testing is performed, slings shall not be used unless repaired, reconditioned and proof tested by the sling manufacturer or an equivalent entity

  • Is the crane inspected prior to use at shift start? Inspect daily crane checklist to see if checklist is being completed.

Chemical Safety

Chemical Safety

  • Does this Area/Department use chemicals as part of any process?

  • Does each container have a label as to its contents?

  • OSHA 1910.1200(f)(6)(i)- The information specified under paragraphs (f)(1)(i) through (v) of this section for labels on shipped containers; or,

    OSHA 1910.1200(f)(6)(ii)- Product identifier and words, pictures, symbols, or combination thereof, which provide at least general information regarding the hazards of the chemicals, and which, in conjunction with the other information immediately available to employees under the hazard communication program, will provide employees with the specific information regarding the physical and health hazards of the hazardous chemical.

  • If labels become illigible, is there a means to mark the container properly?

  • OSHA 1910.1200(b)(4)(i)- Employers shall ensure that labels on incoming containers of hazardous chemicals are not removed or defaced;

  • Does the Supervisor/Manager know how to aquire a Safety Data Sheet, SDS for a chemical?

  • OSHA 1910.1200(b)(4)(ii)- Employers shall maintain copies of any safety data sheets that are received with incoming shipments of the sealed containers of hazardous chemicals, shall obtain a safety data sheet as soon as possible for sealed containers of hazardous chemicals received without a safety data sheet if an employee requests the safety data sheet, and shall ensure that the safety data sheets are readily accessible during each work shift to employees when they are in their work area(s); and,

    OSHA 1910.1200(b)(4)(iii)- Employers shall ensure that employees are provided with information and training in accordance with paragraph (h) of this section (except for the location and availability of the written hazard communication program under paragraph (h)(2)(iii) of this section), to the extent necessary to protect them in the event of a spill or leak of a hazardous chemical from a sealed container.

  • Are all flammable liquids kept in closed containers when not in use?

Portable Hand Tools, Powered & Non-Powered

Portable Hand Tools, Powered & Non-Powered

  • Does this Area/Department use hand tools either powered or non-powered as part of any process?

  • Are all cord-connected, electrically operated tools and equipment effectively grounded or of the approved double insulated type?

  • Are pneumatic hoses on power-operated tools checked regularly for deterioration or damage?

  • Are hand tools such as chisels and punches, which develop mushroomed heads during use, reconditioned or replaced as necessary?

  • All tools are returned to proper storage when not in use.

  • Are disc grinders equipped with necessary guards, i.e. 180° guard?

  • Are broken or fractured handles on hammers, screwdrivers and similar equipment replaced promptly or discarded?

  • Does each portable power tool have a constant pressure switch that will shut off when pressure is released?

  • There are no make-shift or shop-built impact or prying tools in the area?

General Housekeeping

General Housekeeping

  • Are all worksites clean, sanitary and orderly?

  • Hoses, slings, welding leads, power cords, etc. properly stored when not in use, kept clear of traffic, walking and working surfaces and areas.

  • Are work surfaces kept dry or is appropriate means taken to assure the surfaces are slip-resistant?

  • Are workbenches free and clear of all aerosol cans and other propellants?

  • Are holes in the floor or other walking surface repaired properly, covered or otherwise made safe?

  • Is all stock on top shelf of racks stretch-wrapped or secured from falling?

  • All all trash containers adaquately emptied and/or covered?

  • Rate overall housekeeping on a scale of 1-5

  • 1-Very Poor, No Excuse 2-Poor, many defects found 3-Fair, needs attention 4-Good, only 1 or 2 minor issues 5-Excellent, 0 defects

Welding & Hot Work

Welding & Hot Work

  • Does this Area/Department use Welding or Torching equipment as part of any process?

  • Are flashback arrestors or approved flashback valves installed on welding equipment?

  • OSHA 1910.253(e)(3)(ii)(C)(3)- Flash-back protection shall be provided by an approved device that will prevent flame from passing into the fuel-gas system.

    A flashback arrestor or flash arrestor is a special gas safety device most commonly used in oxy-fuel welding and cutting to stop the flame or reverse flow of gas back up into the equipment or supply line and it prevents the user and equipment from damage or explosions.

  • Are all hoses color coded red and green for oxygen and acetylene?

  • OSHA 1910.253(e)(5)(i)- Hose for oxy-fuel gas service shall comply with the Specification for Rubber Welding Hose, 1958, Compressed Gas Association and Rubber Manufacturers Association, which is incorporated by reference as specified in Sec. 1910.6.

    OSHA 1910.253(e)(5)(ii)- When parallel lengths of oxygen and acetylene hose are taped together for convenience and to prevent tangling, not more than 4 inches (10.2 cm) out of 12 inches (30.5 cm) shall be covered by tape.

  • Are all welding cables and tubing free from damage (cuts, burn marks, etc.)?

  • OSHA 1910.253(e)(5)(v)- Hose showing leaks, burns, worn places, or other defects rendering it unfit for service shall be repaired or replaced.

  • Are all combustibles and fire hazards removed from the welding area?

  • OSHA 1910.252(a)(2)(vii)- Relocation of combustibles. Where practicable, all combustibles shall be relocated at least 35 feet (10.7 m) from the work site. Where relocation is impracticable, combustibles shall be protected with flameproofed covers or otherwise shielded with metal or asbestos guards or curtains.

  • Are all welding cylinders free from damage and properly secured?

  • Are all welding leads properly guarded?

  • Are proper shields used to protect personnel from flash exposure during welding operations?

  • Are hoses on portable burning rigs coiled and stored when not in use?

  • No splices in welding leads within 10 feet of electrode holder (“stinger”).

Compressed Gases

Compressed Gases

  • Does this Area/Department use any type of compressed gas in any process?

  • Are cylinders firmly attached to substantial structural member or mounted on cart, not attached to conduit?

  • OSHA 1910.101(a)- "Inspection of compressed gas cylinders." Each employer shall determine that compressed gas cylinders under his control are in a safe condition to the extent that this can be determined by visual inspection. Visual and other inspections shall be conducted as prescribed in the Hazardous Materials Regulations of the Department of Transportation (49 CFR parts 171-179 and 14 CFR part 103). Where those regulations are not applicable, visual and other inspections shall be conducted in accordance with Compressed Gas Association Pamphlets C-6-1968 and C-8-1962, which is incorporated by reference as specified in Sec. 1910.6.

    OSHA 1910.101(b)- "Compressed gases." The in-plant handling, storage, and utilization of all compressed gases in cylinders, portable tanks, rail tankcars, or motor vehicle cargo tanks shall be in accordance with Compressed Gas Association Pamphlet P-1-1965, which is incorporated by reference as specified in Sec. 1910.6.

  • Are cylinders stored so that full and empty cylinders are readily identified?

  • OSHA 1910.253(b)(2)(iii)- Empty cylinders shall have their valves closed.

    OSHA 1910.253(b)(2)(iv)- Valve protection caps, where cylinder is designed to accept a cap, shall always be in place, hand-tight, except when cylinders are in use or connected for use.

    OSHA 1910.253(b)(1)(ii)- Compressed gas cylinders shall be legibly marked, for the purpose of identifying the gas content, with either the chemical or the trade name of the gas. Such marking shall be by means of stenciling, stamping, or labeling, and shall not be readily removable. Whenever practical, the marking shall be located on the shoulder of the cylinder.

  • Stored so that oxygen is separated from fuel gases by 20 feet or a 2-hour rated fire-wall a minimum of 5 feet high?

  • OSHA 1910.253(b)(4)(iii)- Oxygen cylinders in storage shall be separated from fuel-gas cylinders or combustible materials (especially oil or grease), a minimum distance of 20 feet (6.1 m) or by a noncombustible barrier at least 5 feet (1.5 m) high having a fire-resistance rating of at least one-half hour.

  • Are cylinders located clear of sources of heat, traffic, overhead crane loads, etc.?

  • OSHA 1910.253(b)(2)(i)- Cylinders shall be kept away from radiators and other sources of heat.

  • Are cylinders transported by approved cart?

  • OSHA 1910.253(b)(5)(ii)(C)- Valve-protection caps shall not be used for lifting cylinders from one vertical position to another. Bars shall not be used under valves or valve-protection caps to pry cylinders loose when frozen to the ground or otherwise fixed; the use of warm (not boiling) water is recommended. Valve-protection caps are designed to protect cylinder valves from damage.

    OSHA 1910.253(b)(5)(ii)(F)- Cylinder valves shall be closed before moving cylinders.

  • Are all piping identified by color code, tags, etc.?

  • Are all compressed air wands and sources for cleaning reduced to maximum 30 psi?

  • OSHA 1910.242(b)- Compressed air used for cleaning. Compressed air shall not be used for cleaning purposes except where reduced to less than 30 p.s.i. and then only with effective chip guarding and personal protective equipment.

Pedestal Grinders

Pedestal Grinders

  • Does this Area/Department use pedestal grinders to alter material or tools?

  • Do side guards cover the spindle, nut and flange and 75% of the wheel diameter?

  • OSHA 1910.215(a)(2)- Guard design. The safety guard shall cover the spindle end, nut, and flange projections. The safety guard shall be mounted so as to maintain proper alignment with the wheel, and the strength of the fastenings shall exceed the strength of the guard, except:

    OSHA 1910.215(a)(2)(i)- Safety guards on all operations where the work provides a suitable measure of protection to the operator, may be so constructed that the spindle end, nut, and outer flange are exposed; and where the nature of the work is such as to entirely cover the side of the wheel, the side covers of the guard may be omitted; and

    OSHA 1910.215(a)(2)(ii)- The spindle end, nut, and outer flange may be exposed on machines designed as portable saws.

  • Is the work rest used and kept adjusted to within 1/8-inch of the wheel?

  • OSHA 1910.215(a)(4)- Work rests. On offhand grinding machines, work rests shall be used to support the work. They shall be of rigid construction and designed to be adjustable to compensate for wheel wear. Work rests shall be kept adjusted closely to the wheel with a maximum opening of one-eighth inch to prevent the work from being jammed between the wheel and the rest, which may cause wheel breakage. The work rest shall be securely clamped after each adjustment. The adjustment shall not be made with the wheel in motion.

  • Is the maximum RPM rating of each abrasive wheel compatible with the RPM rating of the grinder motor?

  • OSHA 1910.215(d)(1)- Inspection. Immediately before mounting, all wheels shall be closely inspected and sounded by the user (ring test) to make sure they have not been damaged in transit, storage, or otherwise. The spindle speed of the machine shall be checked before mounting of the wheel to be certain that it does not exceed the maximum operating speed marked on the wheel. Wheels should be tapped gently with a light nonmetallic implement, such as the handle of a screwdriver for light wheels, or a wooden mallet for heavier wheels. If they sound cracked (dead), they shall not be used. This is known as the "Ring Test".

  • Is cleanliness maintained around grinders?

  • OSHA 1910.22(a)(1)- All places of employment, passageways, storerooms, and service rooms shall be kept clean and orderly and in a sanitary condition.

  • Are bench and pedestal grinders permanently mounted?

  • OSHA 1910.212(b)- Anchoring fixed machinery. Machines designed for a fixed location shall be securely anchored to prevent walking or moving.

  • Are goggles or face shields always worn when grinding?

  • OSHA 1910.133(a)(1)- The employer shall ensure that each affected employee uses appropriate eye or face protection when 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.

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