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SAFETY AUDIT A KEY
HAZARD IDENTIFICATION
TECHNIQUE
A presentation by
Subbarao
Cholama
ndalam AXA Risk Services
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What is Safety Audit
Verifying the existence and implementation ofelements of occupational safety and health
system and for verifying the systems ability to
achieve defined safety objectives
~~~IS-14489-1998
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CONCERNS OF MANAGEMENT
QUANTITY PRODUCED IN RELATION TO
PRODUCTION SCHEDULE AND MARKET
REQUIREMENT PRODUCT QUALITY
PRODUCTION COSTS
INTEGRATING THE STAKEHOLDERSCONCERNS
Is Safety Important? Not always
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SAFE AND SOUND
A study of top companies in the world indicated
that
Safety and Loss Prevention
Programmes were essential for a
companys prosperity and accepted as
part of good Business'.
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Why do organizations have to bother
about Safety Corporate Strategy
Finance
Human Resources
Marketing, Product Design and Product Liability
Manufacturing and operating policy
Information Management and systems Societal Concerns
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Societal Concerns
Increased concern about the impact on the public
not just the workforce concerned
Public intolerance of risks which do not have clearbenefits to those affected
Readiness to press for retribution on those who
cause harm and to seek compensation
Demand for increased transparency
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Demand for full information and for public
involvement
A willingness to challenge and complain
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Corporate Strategy
Business Mission, Philosophy and codes of ethics
Company image in the community
Environment impact
Management Professionalism
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Finance
Loss Control and cost reduction strategies
Product liability, Legal liability, Property damage
Risk retention or transfer
Investment decisions concerning business
acquisitions
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Human Resources
Work and job structuring
Morale and retaining people
Positive health structure
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Marketing, product design and product
liability Specification of product and service
Legal requirement
International requirement
Consumer protection act
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Manufacturing and operating policy
Design/selection/construction/maintenance of
premises, plant, equipment and substances
Quality management Environment management and waste disposal
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Information management and systems
Identification of data critical to the management of
health and safety
Selection of appropriate performance indicators Use of information technology in the collection
and analysis of essential data.
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Organizations carry out
Safety Audit
Safety Survey
Safety Inspection
Safety Tour
Safety Sampling
HAZOP
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Safety Survey: Detailed examination of a narrower
field of activity-e.g.- key areas revealed by safety
audits
Safety Inspection: Routine inspection-work is
being carried in accordance with procedures etc.
Safety Tour: Unscheduled examination-hazards
are removed-standards are removed
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Safety Sampling: Trained observers record the
number of safety defects seen while touring
specified locations by a prescribed route.Typically tours last for 15 min. and are conducted
at weekly intervals. The unweighted count of
defects is used to portray trends in the safety
situation.
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SAFETY AUDIT
MONITORING
COMPARE ACTUAL
PERFORMANCE -
STANDARDS
COMPREHENSIVE
CONTINUOS
AUDIT
NOT DONE BY
INSIDER
NOT
COMPREHENSIVE-
DEPENDS ON SCOPE
PERIODIC
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DIFFERENT TYPES OF AUDIT
Electrical Audit
Fire Safety Audit
Pressure vessels Audit
Lifting Tackles Audit
Statutory Regulations Compliance Audit
Emergency Communication Audit Pipe lines Audit
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Hardware Software
Humanware
Safety Depends on
Engineering
Procurement
Accident and
incident
analysis
Work permit
Health and
Hygiene
Emergency
PPELeadership
Task
observation
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SAFETY AUDIT
OCCUPIERS ARE REQUIRED TO
DEMONSTRATE THEIR CAPABILITY TO
DESIGN LOCATE OPERATE AND MAINTAINTHEIR FACILITIES TO STANDARDS
ACCEPTABLE TO THE GOVT. AND PUBLIC.
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AUDIT
AN AUDIT IS A SYSTEMATIC
INDEPENDENT REVIEW TO VERIFY
CONFORMANCE WITH ESTABLISHEDGUIDE LINES OR STANDARDS. IT
EMPLOYS WELL DEFINED REVIEW
PROCESS TO ENSURE CONSISTENCE
AND TO ALLOW THE AUDITOR TO REACHDEFENSIBLE CONCLUSIONS.
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OBJECTIVES OF THE SAFETY AUDIT
DESIGN DEFICIENCIES AND ALSOWEAKNESSES WHICH MIGHT HAVE
CROPPED UP DURING MODIFICATIONS
/ADDITIONS.
FIRE PROTECTION ARRANGEMENTS ANDSAFETY SYSTEMS.
OPERATING /MAINTENANCE PROCEDURES-
DEGRADED WITH TIME TRAINING, PREPAREDNESS FOR HANDLING
EMERGENCIES.
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SCOPE OF AUDIT
FIRE AND EXPLOSION; PREVENTION,
PROTECTION AND EMERGENCY
MANAGEMENT. WORK INJURY PREVENTION.
HEALTH HAZARDS CONTROL.
CONSEQUENCES OF EMERGENCIES.
ON SITE EMERGENCY CONTROL
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Elements of Occupational Safety and
Health System-IS14489 Occupational Health and Safety Policy
OS&H organizational set up
Education and Training Employees participation in OS&H Management
Motivational and Promotional measures for
OS&H Safety Manual and Rules
Compliance with Statutory Requirements
New Equipment review and inspection
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Elements contd..
Accident reporting analysis investigation and
implementation and recommendations
Risk Assessment including hazard identification
Safety inspections
Health and safety improvement plan/targets
First aid facilities-Occupational health center
Personal Protective Equipment
Good housekeeping
Machine and general area guarding
Material handling equipment
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Elements contd..
Electrical and Personal safeguarding Ventilation, illumination and noise
Work environment monitoring system
Prevention of occupational diseases includingperiodic medical examination
Safe operating procedures
Work Permit systems
Fire Prevention, Protection and fighting systems
Emergency Preparedness plans(onsite/offsite)
Process Plant modification procedure
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Elements contd..
Transportation of hazardous substances
Hazardous waste treatment and disposal
Safety in storage and warehousing Contractor safety systems
Safety for customers(including MSDS)
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Records to be examined during Audit
OS&H Policy
Safety organization chart
Training Records on safety, fire and first aid
Accident investigation reports
Accidents and dangerous occurrences-Statistics and
analysis
Records of tests and examination of equipment and
structures Safe operating procedures for various operations
Record of work permits
Record of montioring of flammable and explosives
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Records- Contd..
Maintenance and testing records of fire detection
and fire fighting equipment
Medical records of employees
Records of industrial hygiene surveys(noise,
ventilation, illumination levels, airborne and toxicsubstances, explosive gases)
MSDS
Onsite emergency plans and record of mockdrills Records of waste disposal
Records of effluent discharge to the environment
Housekeeping inspection records
Records contd
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Records contd..
Minutes of Safety committee meetings
Approval of layouts and other approvals from statutory
authorities
Records of any modifications carried out in plant and
process
Maintenance procedure records Calibration and testing records
Shutdown maintenance procedures
In service inspection manuals, records including that ofmaterial handling
Safety Budget
Statutory Records, Previous audit reports,
Trans ortation of Hazardous substances
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TOPICS ON WHICH INFORMATION IS
COLLECTED
SAFETY ORGANIZATION.
CONTRACTOR EMPLOYEE ACTIVITIES.
MATERIAL SAFETY DATA. OCCUPANCY.
SAFETY AND HEALTH POLICY.
OPERATION AND MAINTENANCE OFSAFETY MANUAL.
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EXPANSION MODIFICATION -
AUTHORIZATION PROCEDURES.
SAFETY EDUCATION , TRAINING. STATUTORY STANDARDS, SAFETY IF
JOB SAFETY ANALYSIS.
JOB SAFETY INSTRUCTIONS
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.TOPICS CONTD.
SAFETY INSPECTION.
SAFETY OBSERVATIONS.
WORK PERMIT SYSTEM. FIRE PROTECTION ARRANGEMENTS
FIRE EMERGENCY CONTROL
PROCEDURES. WORK ENVIRONMENT MONITORING.
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PERSONAL PROTECTIVE EQUIPMENT.
MEDICAL/AMBULANCE FACILITIES.
ACCIDENT/INCIDENT -REPORTING
INVESTIGATION ANALYSIS.
IDENTIFICATION OF CRITICALEQUIPMENT AND PREUSE INSPECTION
OF CRITICAL EQUIPMENT
OFF THE JOB -SAFETY. STATISTICAL INF. ON LOSSES INJURIES.
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Manufacture, Storage and import of Hazardous Chemicals
Rules, 1989
Safety Audit is required to be carried out by by the
occupiers of both the new and the existing
industrial activities with the help of an expert notassociated with such industrial activities.
This is required under Rule No.10-subrule (4)
This has come into effect from 3/10/94
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Traits of an auditor
Dispel the myth that it is policing on behalf of
management
Is questionnaire useful? Knowledge in the area being visited
Blinkered view?
Discussion is more important-Facilitator ratherthan an inspector.
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Are you a good auditor?
FINISHED FILES ARE THE
RESULT OF YEARS OFSCIENTIFIC STUDY
COMBINED WITH THEEXPERIENCE OF YEARS
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Safety Leadership is key to success
Survey by Linkage, inc., 1999
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Safety Culture
Liveware
Safety Culture
Hardware Software
Acts-Practice-Habit-Behavior-Culture
Coincident or Not ?
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Coincident or Not ?If,
A B C D E F G H I J K L M N O P Q R S T U V W X Y Z
Equals,1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
Then,
K + N + O + W + L + E + D + G + E11 + 14 + 15 + 23 + 12 + 5 + 4 + 7 + 5 = 96%
H + A + R + D + W + O + R + K8 + 1 + 18 + 4 + 23 + 15 + 18 + 11 = 98%
Both are important, but the total falls just short of 100%
But,A + T + T + I + T + U + D + E1 + 20 + 20 + 9 + 20 + 21 + 4 + 5 = 100%
Safety really is about attitude. Make 100% Safe Behavior your choice
both ON and OFF the job
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Safety and Incident Prevention
Depends how much on ATTITUDE ?
A
T
T
I
T
UD
E
=
=
=
=
=
==
=
1
20
20
9
20
214
5
100%