Internal Audit Report Format for Health & Safety

8/13/2019 Internal Audit Report Format for Health & Safety

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Internal Audit Report of __________________________________Hazard Identification, Risk Assessment and Control Measures for Health & Safety Management

TABLE OF CONTENTS

1.0. INTRODUCTION OF COMPANY

2.0. EXECUTIVE SUMMARY

3.0. SCOPE, FOCUS AND OBJECTIVES

4.0. INTRODUCTION OF ASSESSMENT

5.0. HAZARD IDENTIFICATION

6.0. LIST OF IDENTIFIED HIGH RISK AREAS

7.0. DETERMINING CONTROLS & RECOMMENDATIONS


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1.0. INTRODUCTION OF COMPANY:Name and Address

of Company

Telephone Fax

E-mail Website

Year of

Establishment

OwnershipSole

Proprietor

Joint

Venture

Multi-

national

Limited

Liability

Company

Other

(Please

Specify)

Physical Location

Manufacturing Service Other (Please Specify)Type of Activity

Sector

Size of the Facility Small Medium Large

Industrial Process

Used

Production / Service

CapacityCurrent Full Capacity

Market Export Local MixExport %

Local %

Total No. of

Employees

Direct

(Permanent)

Direct

(Casual)

Direct

(Contract)Outsourced Others

Company Highlights

Contact Person(Name &

Designation)

H&S Team

members

Name Designation Section

Leader:


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.0. EXECUTIVE SUMMARY:ompany: Consultant: Region: North / South

ervice Provided: OHS Assessment / OHS Management System Assessment Dates: Report Submission Date:

Identified Measures of OHS Assessment

r.

#

Identified /

Suggested

Measures

(Control Measures)

Identified

Hazard and

Associated

Risk

Severity

1 - 5

Likelihood

of

Occurrence

1 - 5

Total

Impact

(Severity x

Likelihood)

Identified

Associated

Cost

Savings

(Million PKR

per annum)

Responsibe

Person

from

Company

Implementation

Timelines

(Target Dates)

Investment

Required

(Million

PKR)

Pay Back

Period

(Months)

Category

*

Linked Key

Performance

Indicator

(Mention

title only)

1

2

3

4

5

Total


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3.0. SCOPE, FOCUS AND OBJECTIVES

3.1. Scope:Complete supply Chain with in the boundary of company (includes Production, quality /

inspection lab, raw material store, finish goods store, etc.)

3.2. Focus:The focus of one day assessment based on the standard OHSAS 18001:2007 clause 4.3.1

(Hazard identification, risk assessment and determining controls) to ensure betterunderstanding on available hazards at the company, its associated risk and to determine

control of No/Low cost for the betterment of Health & Safety Management of the company.

3.3. Objectives:The assessment has following objectives;

Continuation of learning & training on OHSAS 18001:2007 standard Initiation of Health & Safety Management System at company Identification of hazards & Risk assessment Identify immediate and permanent Control measures against identified high risk

hazards

Improve overall Health & Safety Management system of company


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4.0. INTRODUCTION OF ASSESSMENT:This Hazard identification & Risk assessment program is designed to review the practical

implementation of health and safety arrangements in the manufacturing companies.

Using the severity and probability criteria defined below, the risk factors has been introduced

onto a Risk Matrix based on RISK= PROBABILITYX SEVERITY.

The same formula will follow for calculating the risk of all identified observations / hazards

against the listed questionnaire of hazards which corresponded answer is No. Remedial

actions are necessary on high risk observations for the improvement of Health & Safety

Management of company.

S= Criteria for evaluating the Severity

Category /

Descriptive WordPersonnel Illness/ Injury

5

CATASTROPHICDeath

4

CRITICAL

Severe injury or severe occupational illness

>2 Week hospitalization

3

SIGNIFICANT

Major injury or major occupational illness


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P= Criteria for evaluating the Probability

PROBABILITY

LevelDescriptive

wordDefinition

5 FREQUENT Likely to occur repeatedly in system life cycle

4 PROBABLE Likely to occur several times in system life cycle

3 OCCASIONAL Likely to occur sometime in system life cycle

2 REMOTE Remote occurrence during system life cycle.

1 IMPROBABLE It can be assumed physically impossible to occur

R= Risk Matrix

55 10 15 20 25

44 8 12 16 20

33 6 9 12 15

22 4 6 8 10

11 2 2 4 5

1 2 3 4 5

Legend

20 E: Extreme risk - immediate action required

>10& 20 H: High risk - urgent management attention needed

>5 & 10 M: Medium risk - management attention as soon as possibl

>5 L: Low risk - longer term action may be required

Pr

o

b

a

b

ility

S e v e r i t y


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5.0.HAZARD IDENTIFICATION:5.1. GENERAL WORK ENVIRONMENT

5.1.1. Are all worksites clean and orderly? (No, 9= 3X 3)5.1.2. Are work surfaces kept dry or appropriate means taken to assure the

surfaces are slip-resistant? Are all spilled materials or liquids cleaned up

immediately? (Yes)

5.1.3. Is combustible scrap, debris and waste stored safely and removed from theworksite promptly?

5.1.4. Is combustible dust cleaned up with a vacuum system to prevent the dustgoing into suspension?

5.1.5. Are pits and floor openings covered or otherwise guarded?

5.2. PERSONAL PROTECTIVE EQUIPMENT5.2.1. Are protective goggles or face shields provided and worn where there is

any danger of flying particles or corrosive materials?

5.2.2. Are approved safety glasses required to be worn at all times in areas wherethere is a risk of eye injuries such as punctures, abrasions, contusions or

burns?

5.2.3. Is appropriate foot protection required where there is the risk of footinjuries from hot, corrosive, poisonous substances, falling objects,

crushing or penetrating actions?

5.2.4. Are approved respirators provided for regular or emergency use whereneeded? Is all protective equipment maintained in a sanitary condition and

ready for use?

5.2.5. Where special equipment is needed for electrical workers, is it available?

5.3. WALKWAYS5.3.1. Are aisles and passageways kept clear?5.3.2. Are aisles and walkways marked as appropriate? Are wet surfaces covered

with non-slip materials?


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5.3.3. Are holes in the floor, sidewalk or other walking surface repaired properly,covered or otherwise made safe? Is there safe clearance for walking in

aisles where motorized or mechanical handling equipment is operating.

Are spilled materials cleaned up immediately?

5.3.4. Are materials or equipment stored in such a way that sharp projectiles willnot interfere with the walkway? Are changes of direction or elevations

readily identifiable?

5.3.5. Are aisles or walkways that pass near moving or operating machinery,welding operations or similar operations arranged so employees will not be

subjected to potential hazards?

5.4. FLOOR AND WALL STAIRWAYS5.4.1. Are floor openings guarded by a cover, guardrail, or equivalent on all sides

(except at entrance to stairways or ladders)?

5.4.2. withstand a load of at least 200 pounds?5.4.3. Is the glass in windows, doors, glass walls that are subject to human

impact, of sufficient thickness and type for the condition of use?

5.4.4.

Are grates or similar type covers over floor openings such as floor drains,of such design that foot traffic or rolling equipment will not be affected by

the grate spacing?

5.4.5. Are floor or wall openings in fire resistive construction provided withdoors or covers compatible with the fire rating of the structure and

provided with self-closing feature when appropriate?

5.5. STAIRS & STAIRWAYS5.5.1. Are standard stair rails or handrails on all stairways having four or more

risers? Are all stairways at least 22 inches wide?

5.5.2. Do stairs have at least a 6'6" overhead clearance?5.5.3. Do stairs angle no more than 50 and no less than 30 degrees?5.5.4. Do stairway handrails have a least 1-1/2 inches of clearance between the

handrails and the wall or surface they are mounted on?

5.5.5. Are stairway handrails capable of withstanding a load of 200 pounds,applied in any direction?


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5.6. ELEVATED SURFACES5.6.1. Are signs posted, when appropriate, showing the elevated surface load

capacity?

5.6.2. Are surfaces elevated more than 30 inches above the floor or groundprovided with standard guardrails?

5.6.3. Are all elevated surfaces (beneath which people or machinery could beexposed to falling objects) provided with standard 4-inch toeboards?

5.6.4. Is a permanent means of access and egress provided to elevated storageand work surfaces? Is required headroom provided where necessary?

5.6.5. Is material on elevated surfaces piled, stacked or racked in a manner toprevent it from tipping, falling, collapsing, rolling or spreading?

5.7. EXITING OR EGRESS5.7.1. Are all exits marked with an exit sign and illuminated by a reliable light

source?

5.7.2. Are the directions to exits, when not immediately apparent, marked withvisible signs?

5.7.3. Are doors, passageways or stairways, that are neither exits nor access toexits and which could be mistaken for exits, appropriately marked "NOT

AN EXIT", "TO BASEMENT", "STOREROOM", and the like?

5.7.4. Are all exits kept free of obstructions?5.7.5. Is the number of exits from each floor of a building, and the number of

exits from the building itself, appropriate for the building occupancy load?

5.8. HAND TOOLS & EQUIPMENT5.8.1. Are all tools and equipment (both, company and employee-owned) used

by employees at their workplace in good condition?

5.8.2. Are hand tools such as chisels, punches, which develop mushroomedheads during use, reconditioned or replaced as necessary?

5.8.3. Are broken or fractured handles on hammers, axes and similar equipmentreplaced promptly? Are worn or bent wrenches replaced regularly?


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5.8.4. Are appropriate safety glasses, face shields, and similar equipment usedwhile using hand tools or equipment that might produce flying materials or

be subject to breakage?

5.8.5. Is eye and face protection used when driving hardened or tempered spudsor nails?

5.9. MACHINE GUARDING5.9.1. Is there a training program to instruct employees on safe methods of

machine operation?

5.9.2. Is there adequate supervision to ensure that employees are following safemachine operating procedures? Is there a regular program of safety

inspection of machinery and equipment?

5.9.3. Is all machinery and equipment kept clean and properly maintained?5.9.4. Is sufficient clearance provided around and between machines to allow for

safe operations, set up and servicing, material handling and waste

removal?

5.9.5. Are machinery guards secure and so arranged that they do not offer ahazard in their use?

5.9.6. If special hand tools are used for placing and removing material, do theyprotect the operator's hands?

5.9.7. Are revolving drums, barrels, and containers required to be guarded by anenclosure that is interlocked with the drive mechanism, so that revolution

cannot occur unless the guard enclosure is in place, so guarded?

5.10. COMPRESSORS & COMPRESSED AIR5.10.1. Are compressors equipped with pressure relief valves, and pressure

gauges?

5.10.2. Are compressor air intakes installed and equipped to ensure that only cleanuncontaminated air enters the compressor?

5.10.3. Are air filters installed on the compressor intake?5.10.4. Is the belt drive system totally enclosed to provide protection for the front,

back, top, and sides? Is it strictly prohibited to direct compressed air

towards a person?


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5.10.5. Are employees prohibited from using highly compressed air for cleaningpurposes?

5.10.6. Is it prohibited to use compressed air to clean up or move combustible dustif such action could cause the dust to be suspended in the air and cause a

fire or explosion hazard?

5.11. HOIST & AUXILIARY EQUIPMENT5.11.1. Is each overhead electric hoist equipped with a limit device to stop the

hook travel at its highest and lowest point of safe travel?

5.11.2. Will each hoist automatically stop and hold any load up to 125 percent ofits rated load, if its actuating force is removed?

5.11.3. Are close-fitting guards or other suitable devices installed on hoist toassure hoist ropes will be maintained in the sheave groves?

5.11.4. Are all hoist chains or ropes of sufficient length to handle the full range ofmovement for the application while still maintaining two full wraps on the

drum at all times?

5.11.5. Are only employees who have been trained in the proper use of hoistsallowed to operate them?

5.12. SPRAYING OPERATIONS5.12.1. Is adequate ventilation assured before spray operations are started?5.12.2. Is mechanical ventilation provided when spraying operation is done in

enclosed areas?

5.12.3. Is the electric drying apparatus properly grounded?5.12.4.

Are lighting fixtures for spray booths located outside of the booth and theinterior lighted through sealed clear panels?

5.12.5. Are the electric motors for exhaust fans placed outside booths or ducts?Are belts and pulleys inside the booth fully enclosed?

5.12.6. Do ducts have access doors to allow cleaning? Do all drying spaces haveadequate ventilation?

5.13. ENTERING CONFINED SPACES


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5.13.1. Are confined spaces thoroughly emptied of any corrosive or hazardoussubstances, such as acids or caustics, before entry?

5.13.2. Before entry, are all lines to a confined space, containing inert, toxic,flammable, or corrosive materials valved off and blanked or disconnected

and separated?

5.13.3. Is the atmosphere inside the confined space frequently tested orcontinuously monitor during conduct of work?

5.13.4. Is there an assigned safety standby employee outside of the confinedspace, whose sole responsibility is to watch the work in progress, sound an

alarm if necessary, and render assistance?

5.13.5.

Is there an effective communication system in place whenever respiratoryequipment is used and the employee in the confined space is out of sight of

the standby person?

5.13.6. Is approved respiratory equipment required if the atmosphere inside theconfined space cannot be made acceptable?

5.13.7. If employees will be using oxygen-consuming equipment such assalamanders, torches, furnaces, in a confined space, is sufficient air

provided to assure combustion without reducing the oxygen concentration

of the atmosphere below 19.5 percent by volume?

5.14. ENVIRONMENTAL CONTROLS5.14.1. Are all work areas properly illuminated?5.14.2. Are employees instructed in proper first aid and other emergency

procedures?

5.14.3. Are hazardous substances identified which may cause harm by inhalation,ingestion, skin absorption or contact?

5.14.4. Is personal protective equipment provided, used and maintained whereverrequired?

5.14.5. Are there written standard operating procedures for the selection and useof respirators where needed? Are restrooms and washrooms kept clean and

sanitary?

5.14.6. Is all water provided for drinking, washing, and cooking potable? Are alloutlets for water not suitable for drinking clearly identified?


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5.14.7. Are employees working on streets and roadways where they are exposedto the hazards of traffic, required to wear bright colored (traffic orange)

warning vest?

5.15. FLAMMABLE & COMBUSTIBLE MATERIALS5.15.1. Are combustible scrap, debris and waste materials (i.e. oily rags) stored in

covered metal receptacles and removed from the worksite promptly?

5.15.2. Is proper storage practiced to minimize the risk of fire includingspontaneous combustion?

5.15.3. Are approved containers and tanks used for the storage and handling offlammable and combustible liquids?

5.15.4. Do storage rooms for flammable and combustible liquids have mechanicalor gravity ventilation?

5.15.5. Is liquefied petroleum gas stored, handled, and used in accordance withsafe practices and standards? Are liquefied petroleum storage tanks

guarded to prevent damage from vehicles?

5.15.6. Are all solvent wastes and flammable liquids kept in fire-resistant coveredcontainers until they are removed from the worksite?

5.15.7. Are fuel gas cylinders and oxygen cylinders separated by distance, fireresistant barriers or other means while in storage?

5.15.8. Are appropriate fire extinguishers mounted within 75 feet of outside areascontaining flammable liquids, and within 10 feet of any inside storage area

for such materials?

5.15.9. Is the transfer/withdrawal of flammable or combustible liquids performedby trained personnel?

5.15.10. Are spare portable or butane tanks, which are sued by industrial trucksstored in accord with regulations?

5.16. FIRE PROTECTION5.16.1. Do you have a fire prevention plan?5.16.2. Does your plan describe the type of fire protection equipment and/or

systems?


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5.16.3. Have you established practices and procedures to control potential firehazards and ignition sources? Are employees aware of the fire hazards of

the material and processes to which they are exposed? Is your local fire

department well acquainted with your facilities, location and specific

hazards?

5.16.4. If you have a fire alarm system, is it tested at least annually?5.16.5. Are fire extinguishers recharged regularly and noted on the inspection tag?5.16.6. Are employees periodically instructed in the use of extinguishers and fire

protection procedures?

5.17. HAZARDOUS CHEMICAL EXPOSURES5.17.1. Are employees trained in the safe handling practices of hazardous

chemicals such as acids, caustics, and the like?

5.17.2. Are employees aware of the potential hazards involving various chemicalsstored or used in the workplace-- such as acids, bases, caustics, epoxies,

and phenols?

5.17.3. Have standard operating procedures been established and are they beingfollowed when cleaning up chemical spills?

5.17.4. Where needed for emergency use, are respirators stored in a convenient,clean and sanitary location?

5.17.5. Are respirators intended for emergency use adequate for the various usesfor which they may be needed? Are employees prohibited from eating in

areas where hazardous chemicals are present?

5.17.6. Is personal protective equipment provided, used and maintained whenevernecessary?

5.17.7. Are there written standard operating procedures for the selection and useof respirators where needed? If you have a respirator protection program,

are your employees instructed on the correct usage and limitations of the

respirators?

5.17.8. Are materials, which give off toxic asphyxiant, suffocating or anestheticfumes, stored in remote or isolated locations when not in use?

5.18. HAZARDOUS SUBSTANCES COMMUNICATION


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5.18.1. Is there a list of hazardous substances used in your workplace?5.18.2. Is there a written hazard communication program dealing with Material

Safety Data Sheets (MSDS) labeling, and employee training?

5.18.3. Who is responsible for MSDSs, container labeling, employee training?5.18.4. Is each container for a hazardous substance (i.e. vats, bottles, storage

tanks,) labeled with product identity and a hazard warning (communication

of the specific health hazards and physical hazards)?

5.18.5. Is there a Material Safety Data Sheet readily available for each hazardoussubstance used?

5.19. ELECTRICAL5.19.1. Are your workplace electricians familiar with the Cal/OSHA Electrical

Safety Orders? Do you specify compliance with Cal/OSHA for all contract

electrical work?

5.19.2. Are all employees required to report as soon as practicable any obvioushazard to life or property observed in connection with electrical equipment

or lines?

5.19.3.

Are employees instructed to make preliminary inspections and/orappropriate tests to determine what conditions exist before starting work

on electrical equipment or lines?

5.19.4. When electrical equipment or lines are to be serviced, maintained oradjusted, are necessary switches opened, locked-out and tagged whenever

possible?

5.19.5. Is the use of metal ladders prohibited in area where the ladder or theperson using the ladder could come in contact with energized parts of

equipment, fixtures or circuit conductors?

5.19.6. Are all disconnecting switches and circuit breakers labeled to indicate theiruse or equipment served? Are disconnecting means always opened before

fuses are replaced?

5.19.7. Do all interior wiring systems include provisions for grounding metal partsof electrical raceways, equipment and enclosures?

5.19.8. Is each motor disconnecting switch or circuit breaker located within sightof the motor control device?


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5.20. NOISE5.20.1. Are there areas in the workplace where continuous noise levels exceed 85

dBA? (To determine maximum allowable levels for intermittent or impact

noise, see Title 8, Section 5097.)

5.20.2. Is there an ongoing preventive health program to educate employees insafe levels of noise and exposure, effects of noise on their health, and use

of personal protection?

5.20.3. Is the training repeated annually for employees exposed to continuousnoise above 85 dBA?

5.20.4. Have work areas where noise levels make voice communication betweenemployees difficult been identified and posted?

5.20.5. Is approved hearing protective equipment (noise attenuating devices)available to every employee working in areas where continuous noise

levels exceed 85 dBA?

5.21. IDENTIFICATION OF PIPING SYSTEMS5.21.1. When non-portable water is piped through a facility, are outlets or taps

posted to alert employees that it is unsafe and not to be used for drinking,

washing or other personal use?

5.21.2. When hazardous substances are transported through above ground piping,is each pipeline identified at points where confusion could introduce

hazards to employees?

5.21.3. When pipelines carrying hazardous substances are identified by tags, arethe tags constructed of durable materials, the message carried clearly ad

permanently distinguishable and are tags installed at each valve or outlet?

5.22. MATERIAL HANDLING5.22.1. Is there safe clearance for equipment through aisles and doorways?5.22.2. Are aisle ways designated, permanently marked, and kept clear to allow

unhindered passage? Are motorized vehicles and mechanized equipment

inspected daily or prior to use?

5.22.3. Are vehicles shut off and brakes set prior to loading or unloading?


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5.22.4. When hoisting material or equipment, are provisions made to assure noone will be passing under the suspended loads?

5.22.5. Are Material Safety Data Sheets available to employees handlinghazardous substances?

5.23. CONTROL OF HARMFUL SUBSTANCES BYVENTILATION

5.23.1. Is the volume and velocity of air in each exhaust system sufficient togather the dusts, fumes, mists, vapors or gases to be controlled, and to

convey them to a suitable point of disposal?

5.23.2. Are exhaust inlets, ducts and plenums designed, constructed, andsupported to prevent collapse or failure of any part of the system?

5.23.3. Are clean-out ports or doors provided at intervals not to exceed 12 feet inall horizontal runs of exhaust ducts?

5.23.4. Where two or more different type of operations are being controlledthrough the same exhaust system, will the combination of substances being

controlled, constitute a fire, explosion or chemical reaction hazard in the

duct?5.23.5. Where two or more ventilation systems are serving a work area, is their

operation such that one will not offset the functions of the other?

5.24. SANITIZING EQUIPMENT & CLOTHING5.24.1. Is personal protective clothing or equipment, that employees are required

to wear or use, of a type capable of being easily cleaned and disinfected?

5.24.2. Are employees prohibited from interchanging personal protective clothingor equipment, unless it has been properly cleaned?

5.24.3. Are machines and equipment, which processes, handle or apply materialsthat could be injurious to employees, cleaned and/or decontaminated

before being overhauled or placed in storage?

5.24.4. Are employees prohibited from smoking or eating in any area wherecontaminates are present that could be injurious if ingested?

5.25. EMERGENCY ACTION PLAN


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5.25.1. Are you required to have an emergency action plan?5.25.2. Does the emergency action plan comply with requirements of standard?5.25.3. Have emergency escape procedures and routes been developed and

communicated to all employers? Do employees, who remain to operate

critical plant operations before they evacuate, know the proper procedures?

5.25.4. Is the employee alarm system that provides a warning for emergencyaction recognizable and perceptible above ambient conditions?

5.25.5. For conducting rescue and medical duties?

5.26. VENTILATION FOR INDOOR AIR QUALITY5.26.1. Does your HVAC system provide at least the quantity of outdoor air

required by the State Building Standards Code, Title 24, Part 2 at the time

the building was constructed?

5.26.2. Is the HVAC system inspected at least annually, and problems corrected?Are inspection records retained for at least 5 years?

5.27. HAZARD COMMUNICATION5.27.1. Is there a list of hazardous substances used in your workplace?5.27.2. Is there a written hazard communication program dealing with Material

Safety Data Sheets (MSDS), labeling, and employee training?

5.27.3. Is each container for a hazardous substance (i.e., vats, bottles, storagetanks, etc.) labeled with product identity and a hazard warning

(communication of the specific health hazards and physical hazards)?

5.27.4. Is there a Material Safety Data Sheet readily available for each hazardoussubstance used?

5.27.5. Is there an employee training program for hazardous substances?5.27.6. Does this program include?5.27.7. Are employees trained in the following:5.27.8. How to recognize tasks that might result in occupational exposure?5.27.9. How to use work practice and engineering controls and personal protective

equipment and to know their limitations?


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5.27.10. How to obtain information on the types selection, proper use, location,removal handling, decontamination, and disposal of personal protective

equipment?

5.27.11. Who to contact and what to do in an emergency?

5.0. LIST OF IDENTIFIED HIGH RISK AREAS:S# Observations

Risk

Factor

1

2

3

4

5

6

7

8

9

10

6.0.

DETERMINING CONTROLS & RECOMMENDATIONS:


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1) High Risk Activity / pointType Immediate Solution Permanent solution

Elimination

Substitution

Engineering Controls

Signage, Administrative Controls

PPEs

2) High Risk Activity / pointType Immediate Solution Permanent solution


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Elimination

Substitution



PPEs

4) High Risk Activity / point


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Type Immediate Solution Permanent solution

Elimination

Substitution



PPEs

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