SAFETY AUDIT

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

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

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'.

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

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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• Demand for full information and for public involvement

• A willingness to challenge and complain

Corporate Strategy

• Business Mission, Philosophy and codes of ethics

• Company image in the community• Environment impact• Management Professionalism

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

Marketing, product design and product liability

• Specification of product and service• Legal requirement• International requirement• Consumer protection act

Manufacturing and operating policy

• Design/selection/construction/maintenance of premises, plant, equipment and substances

• Quality management• Environment management and waste disposal

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.

Organizations carry out

• Safety Audit• Safety Survey• Safety Inspection• Safety Tour• Safety Sampling• HAZOP

• 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

• 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.

SAFETY AUDIT

MONITORING • COMPARE ACTUAL

PERFORMANCE -STANDARDS

• COMPREHENSIVE• CONTINUOS

AUDIT• NOT DONE BY INSIDER• NOT COMPREHENSIVE-

DEPENDS ON SCOPE• PERIODIC

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

Hardware Software

Humanware

Safety Depends on

•Engineering

•Procurement

•Maintenance

•Accident and incident analysis

•Work permit

•Health and Hygiene

•Emergency

•PPE

•Leadership

•Task observation

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.

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.

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.

SCOPE OF AUDIT

• FIRE AND EXPLOSION; PREVENTION, PROTECTION AND EMERGENCY MANAGEMENT.

• WORK INJURY PREVENTION.• HEALTH HAZARDS CONTROL.• CONSEQUENCES OF EMERGENCIES.• ON SITE EMERGENCY CONTROL

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

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

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

Elements contd..

• Transportation of hazardous substances• Hazardous waste treatment and disposal• Safety in storage and warehousing• Contractor safety systems• Safety for customers(including MSDS)

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 monitoring of flammable and explosives

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

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, transport of

hazardous substances

TOPICS ON WHICH INFORMATION IS TOPICS ON WHICH INFORMATION IS COLLECTEDCOLLECTED

• SAFETY ORGANIZATION.

• CONTRACTOR EMPLOYEE ACTIVITIES.

• MATERIAL SAFETY DATA.

• OCCUPANCY.

• SAFETY AND HEALTH POLICY.

• OPERATION AND MAINTENANCE OF SAFETY MANUAL.

• EXPANSION MODIFICATION -AUTHORIZATION PROCEDURES.

• SAFETY EDUCATION , TRAINING.• STATUTORY STANDARDS, SAFETY IF• JOB SAFETY ANALYSIS.• JOB SAFETY INSTRUCTIONS

.TOPICS CONTD.

• SAFETY INSPECTION.• SAFETY OBSERVATIONS.• WORK PERMIT SYSTEM.• FIRE PROTECTION ARRANGEMENTS• FIRE EMERGENCY CONTROL PROCEDURES.• WORK ENVIRONMENT MONITORING.

• 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.

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

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.

Are you a good auditor?

• FINISHED FILES ARE THE RESULT OF

YEARS OF SCIENTIFIC STUDY

COMBINED WITH THE EXPERIENCE

OF YEARS

PROCEDURES AND PROTOCOLSAs with any well-functioning management system, an audit program must have guidelines and procedures to describe how an audit should be conducted and what corrective action should be taken.These procedures should define all audit activities, such as planning the audit, onsite activities, and follow-up. Without written audit procedures, the audits will be conducted based on individual skills and preferences and will be conducted inconsistently at best.

A key audit tool is the protocol, which guides the auditor through the audit process.

Some companies use check-lists or questionnaires as protocol.

A check-list or questionnaire may be appropriate for an experienced auditor, but will not be an effective tool for new auditors.

An effective protocol will define the steps that an auditor needs to take in order to audit a particular PSM element and provide guidance on what to look for and where to look for it.

PLANNING The time available for auditing onsite is limited;

therefore, the best way for an audit team to spend their time on site constructively is by effectively planning for the audit.

Pre-audit planning allows audit team to become familiar with the facility and its PSM program before arriving on site, thus spending its efforts on site auditing rather than dealing with administrative details.

An excellent way of obtaining information concerning the facility and its PSM program is by sending out a pre-audit questionnaire.

It is also important to identify an individual at the site to be audited to be the audit coordinator who assists

with the logistical details including setting up interviews and locating documents.

The pre-audit questionnaire and the audit coordinator can be invaluable in determining how much time is necessary to conduct an effective audit.

All too often the audit team is constrained by how long the audit can be or the size of the audit team thus potentially resulting in insufficient time to dig deep enough during the audit to uncover issues other than those that are obvious.

The level of effort that OSHA has expended during some of their “wall-to-wall” inspections can be ten or more times that for a typical company PSM audit.

When audit teams are constrained by the allowable time on site and/or number of team member, pre-audit planning becomes that much more important. For an audit to be effective, the auditor must have sufficient time to interview key individuals involved in implementing the program, review written procedures, review appropriate documentation and to test the system.

The team can spend time before the audit, scheduling key interviews and ensuring that important PSM procedures and documents are available to the audit team at the start of the audit.

As a result, the audit team can spend more time on site testing the effectiveness of the facility’s PSM programs rather than running around trying to schedule interviews and finding important documents.

Most audits do a decent job in interviewing key individuals and reviewing written procedures and documents, but generally fail in testing the system. For example, because of time constraints, usually

resulting from poor pre-audit planning, many auditors will review training records, which, by definition, are available only for those individuals who have been trained.

The auditor spends most of his time on administrative details rather than ensuring that all employees required to be in the training program actually are, that the employees understand the training, the training content is consistent with their roles and responsibilities, etc.

Also, poor pre-audit planning may result in too many auditors for the size of the facility.

If there are too many auditors, they will be fighting over scheduling interviews with key facility safety staff.

Safety Leadership is key to success

Safety Culture

• Liveware

• Safety Culture

• Hardware Software

Acts-Practice-Habit-Behavior-Culture

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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

Safety and Incident PreventionSafety and Incident Prevention

Depends how much on ATTITUDE ?Depends how much on ATTITUDE ?

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AATTTTIITTUUDDEE

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