Copyright 2011 Safety Audits that Safety Audits that Protect Employees & Protect Employees & Business Business American Society of Safety Engineers (ASSE) American Society of Safety Engineers (ASSE) Professional Development Webinar Professional Development Webinar
Copyright 2011 Conducting Health & Safety Audits that Protect Employees & Business American Society of Safety Engineers (ASSE) Professional Development.
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Copyright 2011
Conducting Health & Safety Audits Conducting Health & Safety Audits that Protect Employees & Businessthat Protect Employees & Business
American Society of Safety Engineers (ASSE)American Society of Safety Engineers (ASSE)
Professional Development Webinar Professional Development Webinar
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INSTRUCTORINSTRUCTOR
David Regelbrugge, CIH, CSPSenior Manager – Environmental Health & Safety
ENVIRON
333W. Wacker Drive, Suite 2700
Chicago, IL 60606
312-288-3850
www.environcorp.com
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INTRODUCTIONINTRODUCTION
Why conduct safety audits in the workplace?–Protect employees
The silence of the boardroom
Death in a confined space
–Protect businessSignificant increase in OSHA citation costs
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OBJECTIVEOBJECTIVE
You will be able to:– Identify the basic steps and procedures in
a safety audit and inspection–Applies to general industry
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IntroductionIntroduction
Six steps to conduct a safety inspection1. Initial research 2. Opening meeting and walkthrough3. Review written programs & records4. Detailed walkthrough 5. Review findings 6. Follow-up
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Step 1: Initial ReviewStep 1: Initial Review
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Initial ReviewInitial Review
Prior to arriving on site– Two types of audit
1. Formal Software/Company’s own audit form OHSAS 18001
Comprehensive Time consuming
2. Informal Walkthrough type audit
Extensive experience requiredOnly identifies deficiencies
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Initial ReviewInitial Review
Prior to arriving on site (cont.)–Send pre-audit questionnaire–Review data on the facility
Visit the companies web site
–Review OSHA Stats www.osha.gov/oshstats/index.html
Establishment searchAssist in identifying past concernsLimited
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Initial ReviewInitial Review
Formal & Informal Audits –Checklist available?• Commercial software & checklist• South Carolina OSHA (http://www.scosha.llronline.com/)• Search “Checklist”• South Carolina Department of Labor, Licensing and Regula
tion.mht• genind.pdf
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Step 2: Step 2: Opening Meeting & WalkthroughOpening Meeting & Walkthrough
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Opening Meeting & Opening Meeting & WalkthroughWalkthrough
Initial Meeting & Walkthrough– Meeting
•Become familiar with the people and processes– Walkthrough
General conditions and cleanliness PPE worn when necessarySignage
Confined space, electrical, asbestos materials, etc. – Noise
Hearing protection worn– Fall protection
Railings where needed-toe boards Screens over skylights
– Fork truck usage Load handling Parking with forks resting on the floor
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Step 3: Step 3: Review Records & ProgramsReview Records & Programs
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Review Records & Review Records & ProgramsPrograms
OSHA 300 Log / 300A– Information on serious accidents & injuries–Review the last 5 years
Look for: Excess injuries (e.g., serious cuts, foreign body in eye,
etc.) Cumulative trauma disorders (CDT’s/Ergonomics)
Sprains & strains to the wrist, elbow, shoulder, back, etc.
Insurance claims
First-aid logs (if available)
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Accident investigation forms (if available)–Root cause analysis performed?
True follow-up or simply filling out forms Poor follow-up:
“Employee need to pay attention”“Employee was careless”“Employee needs to be more careful”
Good follow-up:Photographs takenMultiple groups involved including injured employeeRoot cause identified and corrected
Review Records & Review Records & ProgramsPrograms
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Common written programs that may be needed– Hazardous materials (asbestos, lead, etc.)– Emergency Action/Spill Response Plan– Fire Protection Plan– Personal Protective Equipment (PPE) hazard assessment– Respiratory Protection Plan– Confined Space Program– Bloodborne Pathogens– Hearing Conservation Program– LOTO– Hazard Communication
Review Records & Review Records & ProgramsPrograms
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Review Records & Review Records & ProgramsPrograms
Hazardous Materials–Asbestos–Lead–Hexavalent Chromium –Benzene –Cotton dust –Others…
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Emergency Action/Spill Response Plan–What to do in the event of an emergency
Fire, flood, earthquake, severe weather, work place violence, etc.
–Should include evacuation maps–May include additional emergency
informationFire extinguisher useSpill response etc.
–Training/drills?
Review Records & Review Records & ProgramsPrograms
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PPE Hazard Assessment–All task reviewed• Must be written• Information on how workers will be protected must be described
Safety glasses, steel toed shoes, gloves, respirators, hearing protection, etc.
–Signed–Training
Review Records & Review Records & ProgramsPrograms
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Respiratory Protection ProgramVoluntary use
Appendix D distributed to employees
Mandatory use Written program available End of service life change cycle developed Fit testing Medical Annual training
Review Records & Review Records & ProgramsPrograms
Review Records & Review Records & ProgramsPrograms
Confined space program– Site survey performed – If confined spaces are on
sitePermit vs. Non-permitted determined
– If permitted spaces present•Labeled appropriately•Entry procedures developed
Permits Entry equipment Non-entry rescue
•Equipment available
– Training– Annual rescue
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Bloodborne Pathogens– Is first aid administered at the facility–Could employees be exposed to bodily
fluids – If yes
Written Exposure Control Plan Annual trainingHepatitis B vaccination offered
Denials documented
Review Records & Review Records & ProgramsPrograms
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Hearing conservation program– Noise study completed
Employee exposures above 85 dBA (Dose of 50%) If yes
Hearing protection availableAudiometric testing performedAnnual training conducted
Exposures > 90 dBA (Dose of 100%) HP must be worn Employer investigated administrative and/engineering
controls
Review Records & Review Records & ProgramsPrograms
Review Records & Review Records & ProgramsPrograms
Lock-Out/Tag-Out (LOTO)– Regulates the isolation of hazardous energy
Electrical, mechanical, pneumatics, gravity, etc.
– General requirements Written program available Specific energy control procedures (ECPs) available for each piece of equipment Employees must be trained Annual audit performed and documented
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Hazard Communication–Written program available
Inventory of hazardous material completed MSDSs management Labeling addressed
–Training provided Requirements of standard & hazards
addressed Specific hazards addressed
Review Records & Review Records & ProgramsPrograms
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Step 4: Step 4: Detailed WalkthroughDetailed Walkthrough
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Detailed WalkthroughDetailed Walkthrough
What to look for:–Unsafe conditions–Unsafe acts
Detailed WalkthroughDetailed Walkthrough
Unsafe Conditions– House keeping– Exits– Electrical– Fall Protection– Stairs– Ladders
– Machine guarding– Flammable Storage– Fire Protection– Emergency showers
& eyewashes– Material handling
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Detailed WalkthroughDetailed Walkthrough
General house keeping–Walkways clean, dry and clear–Work materials picked up
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Detailed WalkthroughDetailed Walkthrough
Exits–Well marked & lit–Aisle ways to exits• At least 36” wide • Unobstructed
–Unlocked–Open outward
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Detailed WalkthroughDetailed Walkthrough
Electrical– Training
• Authorized employees trained– Transforms & Sub-station
Protected By fence wall etc. Warning signs present
– Electrical wiring Unexposed Junction boxes covered Knock outs in place or blanks installed GFIs present outdoors & in wet locations
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Detailed WalkthroughDetailed Walkthrough
Electrical (Continued)– Extension cords & plugs
Condition No splices
Extension cords not to be used for fixed equipment Not to pass through walls, windows, or doors
Ground on cords intact– Electrical panels
LabeledCoveredDisconnects labelArea in front of panel unobstructed with at least 36” of clearance
Detailed WalkthroughDetailed Walkthrough
Fall Protection– All floors openings and
platforms 4 feet above ground must be guarded
Rails commonly used Standard rail consist of a top rail
(42” above surface), mid-rail (21” above surface) and toe board (4” above surface)
Rail must withstand at least the minimum 200 pounds top rail pressure with a minimum of deflection
Image credit: MSHA.gov
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Fall Protection (Continued)– If railings or other means are not feasible
to protect employees a fall restrain system must be use.Full body harness with suitable lanyard and anchorTraining
Detailed WalkthroughDetailed Walkthrough
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Detailed WalkthroughDetailed Walkthrough
Stairs – Carry a load of five times the normal live load
anticipated – See 29CFR1910.24 for rise and tread dimensions – Angles to the horizontal of between 30 deg. and
50 degrees – Handrails available– Stable– Clean, dry and clear– Emergency escape stairwells
Flammables materials must not be stored hereEmergency lighting and/or illumination required
Detailed WalkthroughDetailed Walkthrough
Ladders– Fixed
Permanently attachedCage required if > 20 feetBroken if > 30 feet
Plat forms or ladder climber safety device
Rungs must be clean and in good condition
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Detailed WalkthroughDetailed Walkthrough
Mobile ladders and stairs– Clean and in good condition– Stops/pads present and in good condition– Don’t stand on two top rungs or steps– Non-conductive– Must extend 3’ beyond upper landing for leaning
ladders– Use 4 to 1 rule for positioning for leaning ladders
Count number of rungs from ground to top and divide by four, this is how far the bottom of the ladder should be placed away from the wall
Image credit: OSHA
Detailed WalkthroughDetailed Walkthrough
Machine guarding– General rule of thumb
“If employees could be caught in or struck by, it should be guarded”
A few examples of items that must be guarded:Shafts, belts, chains, pulleys,
flywheels, moving arms, rotating cylinders, conveyor belts, etc.
Moving parts must be completely guarded
i.e., employees can’t reach around, go under, etc.
Image credit: 8020guarding.com
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Detailed WalkthroughDetailed Walkthrough
Machine Guarding (Continued)– If guards can be opened
Must be interlocked
– Guards come in all shapes and sizes– Guards must be replaced after
maintenance– Guards must be secure– Employees will over ride guards
Detailed WalkthroughDetailed Walkthrough
Machine Guarding (Continued)– Conveyor machine rollers that cannot be
completely guarded must have an emergency pull stop
Image credit: Rockfordsystems.com
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Detailed WalkthroughDetailed Walkthrough
Flammable Storage– Small quantities of flammables (generally less than 55
gallons)• Store in a flammable storage cabinet
– Large quantities of flammable materials (>55 gallons) • Stored in a flammable storage room
General requirements for flammable storage room: Constructed of non-flammable materials Ventilated – at 6 air changes an hour Measures in place to contain spills Explosion proof electrical fixtures Fire suppression system in place When dispensing grounding & bonding must be used “NO SMOKING” posted
– A more complete description is available in 29CFR1910.106
Detailed WalkthroughDetailed Walkthrough
Fire protection– Fire extinguishers must be
strategically placed throughout the work area• Should be clearly identified• Documented inspections
Monthly Annually
– Employees expected to use fire extinguishers must be trained in their use
Image credit: OSHA
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Emergency eyewashes & showers– Must be located in areas where strong acids,
bases or other hazardous chemicals are used.– Located within 10 feet or 10 seconds’ of travel
time– Unobstructed path– Inspected monthly
document
– Tempered water– Able to flush for at least 15 minutes
Detailed WalkthroughDetailed Walkthrough
Detailed WalkthroughDetailed Walkthrough
Material handling– Aisles
Remain open and clearWalkways marked
– Fork trucks operators trained and licensed.
– Fork truck inspections completed daily
– Drivers use horns– Trucks equipped with
lights & back-up alarms– Loads handled and
stacked properly– Load ratings on
mezzanines– Speed??
Detailed WalkthroughDetailed Walkthrough
Unsafe acts– Infinite
Human behavior can be unpredictable
Be on the look out at all times
If an unsafe act is observed ask questions
Image credit: Microsoft
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Review FindingsReview Findings
At the end of the audit –Sit down with client and review finding–Solutions should be offered for any
deficiencies found–Client should not be surprised when final
report/audit is issued
Image credit: Microsoft
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Step 6: Step 6: Follow-upFollow-up
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Follow-upFollow-up
All items identified in the initial audit/inspection should be tracked to identify when they have been corrected–Time frame
Weeks or months after the original audit
–Responsibility should be assigned at the plant level
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ConclusionConclusion
Effective auditing can reduce injuries and citations, thereby reduce operating costs
Best of all, everyone goes home healthy
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Questions?Questions?
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