Elements of an Effective Safety Audit System

Module 2Johnanewquist@gmail.com

815-354-6853

Draft 5 27 2013

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

Top 30 Company Audit (VPP)Element Element Name # Questions Auditor Name

1 Site Health and Safety Policy 52 H&S Expectations & Performance Appraisals 93 Hazard Analysis and Regulatory Compliance 164 Employee Involvement 185 Health and Safety Specialist 76 Accident Reporting, Investigation and Follow-up 247 Health and Safety Training 128 Health and Safety Housekeeping and Inspections 209 Personal Protective Equipment 20

10 Contractor Safety 3311 Emergency Preparedness and Fire Prevention 2212 Safety Risk Assessment (JSA) 2213 High Risk Operations 3814 Management of Change and Preventive Maintenance 1815 Industrial Hygiene 4616 Chemical Management 3517 Ergonomics 3418 Motor Vehicle Safety 2819 Medical Services 5220 Program Evaluation 721 Lock Out Tag Out (LOTO) 35

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)

VPP Company ExpectationsExamples 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.

Insurance Trust Quarterly Audit

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:

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%

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

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.

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.

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

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.

Global Risk Pyramid

Catastrophic

Multiple Fatality

Fatality

Serious Injury (M)

Minor Injury

Property Damage

Close Call

Behavior

EffortFree lessons

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

Safety and Health Training Auditing

• What do you train on?• Is there a training

completion goal?• How do you handle

missed training?

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

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.)

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

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

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.

Job Hazard Analysis

• National Tire Shop• What potential hazard

would be caught with a JHA?

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

Dow 30 Heat Map

• Audit is focusing on High Risk/High Severity items.

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.

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

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.

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