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SAFETY AUDIT A KEY
HAZARD IDENTIFICATION
TECHNIQUE
A presentation by
Subbarao
•Cholamandalam AXA Risk Services
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What is Safety Audit
Verifying the existence and implementation of
elements of occupational safety and health
system and for verifying the system’s 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 STAKEHOLDERS
CONCERNS
•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
company’s 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 clear
benefits 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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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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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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• Safety SurveySafety Survey: Detailed examination of a narrower
field of activity-e.g.- key areas revealed by safety
audits
• Safety InspectionSafety Inspection: Routine inspection-work is
being carried in accordance with procedures etc.
• Safety TourSafety Tour: Unscheduled examination-hazards
are removed-standards are removed
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• Safety SamplingSafety 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
• OCCUPIERS ARE REQUIRED TO
DEMONSTRATE THEIR CAPABILITY TO
DESIGN LOCATE OPERATE AND MAINTAIN
THEIR FACILITIES TO STANDARDS
ACCEPTABLE TO THE GOVT. AND PUBLIC.
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AUDITAUDIT
• AN AUDIT IS A SYSTEMATIC
INDEPENDENT REVIEW TO VERIFY
CONFORMANCE WITH ESTABLISHED
GUIDE LINES OR STANDARDS. IT
EMPLOYS WELL DEFINED REVIEW
PROCESS TO ENSURE CONSISTENCE
AND TO ALLOW THE AUDITOR TO REACH
DEFENSIBLE CONCLUSIONS.
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OBJECTIVES OF THE SAFETY AUDIT
• DESIGN DEFICIENCIES AND ALSO
WEAKNESSES WHICH MIGHT HAVE
CROPPED UP DURING MODIFICATIONS
/ADDITIONS.
• FIRE PROTECTION ARRANGEMENTS AND
SAFETY 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 including
periodic 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 toxic
substances, explosive gases)
• MSDS
• Onsite emergency plans and record of mockdrills
• Records of waste disposal
• Records of effluent discharge to the environment
• Housekeeping inspection records
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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 of
material handling
• Safety Budget
• Statutory Records, Previous audit reports,
Transportation of Hazardous substances
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TOPICS ON WHICH INFORMATION ISTOPICS ON WHICH INFORMATION IS
COLLECTEDCOLLECTED
• SAFETY ORGANIZATION.
• CONTRACTOR EMPLOYEE ACTIVITIES.
• MATERIAL SAFETY DATA.
• OCCUPANCY.
• SAFETY AND HEALTH POLICY.
• OPERATION AND MAINTENANCE OF
SAFETY MANUAL.
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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 CRITICAL
EQUIPMENT 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 not
associated 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 rather
than an inspector.
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Are you a good auditor?
• FINISHED FILES ARE THE
RESULT OF YEARS OF
SCIENTIFIC STUDY
COMBINED WITH THE
EXPERIENCE OF YEARS
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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 + E
11 + 14 + 15 + 23 + 12 + 5 + 4 + 7 + 5 = 96%
H + A + R + D + W + O + R + K
8 + 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 + E
1 + 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 ?Depends how much on ATTITUDE ?
AA
TT
TT
II
TT
UU
DD
EE
=
=
=
=
=
=
=
=
1
20
20
9
20
21
4
5
100%
Editor's Notes
<number>
ATTITUDE!
Just for fun, and to help everyone remember its importance for having a successful safety program, try this clever little word game.
Assign values in alphabetical order from 1 to 26 for each character of the alphabet. A = 1, B = 2, etc.
Write each letter of the word “ATTITUDE” in a vertical column.
Place its assigned value to the right of each letter.
Total the values and discover …. The percentage of impact that attitude has on the success or failure of every safety program.
The attitude of management towards safety must be one of solid affirmation.
The attitude of supervisors towards safety must be one of proactive support.
The attitude of workers towards safety must become very personal.
How do we influence safety and what do we plan to get from our efforts ….(go to next slide)...
