Elements of an Effective Safety Audit

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Is your safety audit process stale with the organization's business plan?
Avoid the common pitfalls that derail most safety audits.
Identify policies and conditions that cause loss and incidents with the examples here in this presentation.
Build the necessary elements of the written audit document.
Author John Newquist has worked with several of the Fortune 500 companies in auditing safety management systems and best practices to prevent injuries and losses for the last 30 years. This was one session presented in a day long seminar in June 2013.

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Elements of an Effective Safety Audit

  1. 1. Elements of an Effective Safety Audit System Module 2 Johnanewquist@gmail.com 815-354-6853 Draft 5 27 2013
  2. 2. 4 Elements to Audit • Management Leadership and Employee Involvement • Worksite Analysis • Hazard Prevention and Control • Safety and Health Training Effective Safety and Health Management System
  3. 3. Top 30 Company Audit (VPP) Element Element Name # Questions Auditor Name 1 Site Health and Safety Policy 5 2 H&S Expectations & Performance Appraisals 9 3 Hazard Analysis and Regulatory Compliance 16 4 Employee Involvement 18 5 Health and Safety Specialist 7 6 Accident Reporting, Investigation and Follow-up 24 7 Health and Safety Training 12 8 Health and Safety Housekeeping and Inspections 20 9 Personal Protective Equipment 20 10 Contractor Safety 33 11 Emergency Preparedness and Fire Prevention 22 12 Safety Risk Assessment (JSA) 22 13 High Risk Operations 38 14 Management of Change and Preventive Maintenance 18 15 Industrial Hygiene 46 16 Chemical Management 35 17 Ergonomics 34 18 Motor Vehicle Safety 28 19 Medical Services 52 20 Program Evaluation 7 21 Lock Out Tag Out (LOTO) 35
  4. 4. Top 30 Site Safety Policy Audit • Is there a written Health & Safety policy, signed by the current operation business leader(s)? • Is the written policy readily available and communicated to all employees? • Does the written Health & Safety Policy assign responsibilities to employees and all levels of management? • Are Health & Safety measurements incorporated into the operation business metrics? • Can employees describe the safety and health objectives for the worksite? • EHS I&I < 0.8 • Audit Ready with a closure rate >= 95% • Promote active participation amongst staff (75% or greater on teams)
  5. 5. VPP Company Expectations Examples of H&S Management expectations include • attending H&S training, • conducting accident investigations, • conducting inspections, • closing action items, • performing safety observations, • using proper work practices, • reporting unsafe conditions immediately, and • wearing proper PPE. • verify through document review and employee interviews.
  6. 6. Insurance Trust Quarterly Audit
  7. 7. Ergo Audit Element • A. Have you identified and listed three ergonomic hazards? • B. List ergonomic corrective actions within last 12 months • C. If you have had claims with the root cause of ergonomics, were corrective measures taken? • D. Annual documented training on ergonomics (back safety, preventing hand fatigue, material handling) for all employees based on claim history. Is an outline or explanation of training available? • E. Are there material handling procedures implemented with a maximum single-person lift capacity? • Where posted:
  8. 8. Insurance Trust Results • 0.84 EMR • ~20% members had no work comp claims in 2012 • 42% loss ratio vs. Ind Avg 60% • ~50% of members had audit score of 90%
  9. 9. 4 Elements to Audit • Management Leadership and Employee Involvement • Worksite Analysis • Hazard Prevention and Control • Safety and Health Training Effective Safety and Health Management System
  10. 10. Employee Participation • Daily pre-job briefings • Daily Morning Action Plan (MAP) meetings and • Operation Hazard Analyses (OHA), • Stop Think Review • Complete audits by ipad or other tablets Fire protection audits should be performed on buildings under construction.
  11. 11. Large Partnership Company • 1600 near misses and hazards brought up by employees in 6 plants. • Employees look out for each other • Incentives focus on leading indicators • This is what you want! • Employees bringing up safety, production, quality, property, environmental and customer service issues. • Use their experiences, eyes and ears.
  12. 12. OFI = Good Catch • Any hazard or unsafe condition is a $20 gas card. • Recognized at monthly safety meeting • 2,000 Good Catches in 4 years • 1,000 employees • 2008 TCIR 1.21 to 0.72 to 0.56 • 2.1 million hours = 0.28 incident rate in 2011
  13. 13. Find and Fix Action Cards • Employees are encouraged to submit their concerns on “Find and Fix Action Cards” to resolve any safety or health issues. • OH VPP site • 345 Actions Cards in last 18 months. • ~1000 total since 2008-2012.
  14. 14. Global Risk Pyramid Catastrophic Multiple Fatality Fatality Serious Injury (M) Minor Injury Property Damage Close Call Behavior Effort Free lessons
  15. 15. 4 Elements to Audit • Management Leadership and Employee Involvement • Worksite Analysis • Hazard Prevention and Control • Safety and Health Training Effective Safety and Health Management System
  16. 16. Safety and Health Training Auditing • What do you train on? • Is there a training completion goal? • How do you handle missed training?
  17. 17. Region V Safety & Health Chapters • Chapter 1 – Introduction • Chapter 2 – Safety and Health Management System • Chapter 3 – Safety and Health Metrics/Tracking • Chapter 4 – Regional Office • Chapter 5 – Area Office • Chapter 6 - Office Safety and Health • Chapter 7 - Emergency Contingency Plan • Chapter 8 - PPE • Chapter 9 - Vehicular Operations • Chapter 10 - Violence in the Workplace • Chapter 11 - Walking/Working Surfaces • Chapter 12 - Hazard Communication • Chapter 13 - Control of Hazardous Energy Sources • Chapter 14 - Permit Required Confined Spaces • Chapter 15 - First Aid & CPR • Chapter 16 - Hearing Conservation Program • Chapter 17 - Fall Protection • Chapter 18 - Respiratory Protection • Chapter 19 - Bloodborne Pathogens • Chapter 20 - Ergonomics • Chapter 21 - Radiation • Chapter 22 - Electrical Safety • Chapter 23 - Protection During Incident Investigation • Chapter 24 - Employee Assistance • Chapter 25 - Medical Management • Chapter 26 - Decontamination • Chapter 27 – Policy and Procedures for Field Staff Exposure
  18. 18. Sample Training Audit Measures • Annual Audit. • Percent completion of mandatory training; • Percent completion of annual physicals; • Percent completion of respirator fit tests; • Percent completion of required annual exercises (such as Continuity Of Operations Plan, Shelter In Place Plan, Emergency Action Plan etc.)
  19. 19. Training & Education Audit • % of Managers/Supervisors completing safety leadership training • Number of H&S meetings conducted • % of employee attendance at H&S meetings • % employees completing required compliance training • % persons leading a safety meeting • % of employees completing required training
  20. 20. 4 Elements to Audit • Management Leadership and Employee Involvement • Worksite Analysis • Hazard Prevention and Control • Safety and Health Training Effective Safety and Health Management System
  21. 21. One VPP Company • Job Hazard Analysis is completed as part of every job • Pre-Job Briefs are required for all work performed at the station. • All briefs are required to include job hazards, special precautions, and appropriate personal protective equipment. • Industrial hygiene surveys for asbestos, lead, noise, and radiation have been conducted and programs have been developed as Control Programs.
  22. 22. Job Hazard Analysis • National Tire Shop • What potential hazard would be caught with a JHA?
  23. 23. 4 Elements to Audit • Management Leadership and Employee Involvement • Worksite Analysis • Hazard Prevention and Control • Safety and Health Training Effective Safety and Health Management System
  24. 24. Dow 30 Heat Map • Audit is focusing on High Risk/High Severity items.
  25. 25. Track Like VPP • 2/21/2011 - Teammates thought top hand rails in the melt shop needed to be free of signage. Signs were removed and relocated to bottom rails on 3/1/2011. • 2/1/2010 - Teammates reported concerns with man baskets that are sold as attachments to forklifts and it was decided to do away with all on the property on 3/3/2010.
  26. 26. Construction Pre-Qualification – Years Experience in Work Process – Experience Modification Rate (EMR) – OSHA Total Recordable Incident Rate and Lost Work day Case Rate Information – Safety Programs – Training Documentation
  27. 27. 2009 Empress Casino Fire • $340 million in damage • Lawsuit blames the fire on general contractor and five other companies • The suit claims a welder inadvertently sparked the blaze in the kitchen area, which ignited greasy cooking residue and spread flames throughout the attic and truss space.
  28. 28. Questions? Find me on Linked in, Twitter, Facebook!

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