Safety Audit Feb 3 2010

7/30/2019 Safety Audit Feb 3 2010

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Date:

Business Unit (s):Location:

Auditor(s):

Key Findings:

Construction Safety Audit Results:

Serang, Indonesia

Location/Business Unit representatives present during the assessment:

CARGILL, INC.

CONTRACTOR SAFETY AUDIT FORM

February 3, 2010

Cargill Animal Nutrition

Overview of Construction Project

New Warehouse Construction,

Extruding Tower Construction

Genset Expansion

85% 90% 95% 100%

Project Planning

Contractor Selection

Contractor Safety BestPractice

Site Inspection

Total Rating

100%

100%

95%

91%

96%


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ASSESSMENT CATEGORY

Points

Possible

Points

Awarded % Percent

I. Project Planning I. A. Zero Injury Expectations (12) 12 12 100%I. B. Project Safety Budgets (8) 8 8 100%I. C. Project Safety Staffing: Projects > $ 5 Million (40) 40 40 100%I. D. Project Safety Staffing: Projects < $ 5 Million (40) 0 0 0%I. E. Constructability Reviews (15) 15 15 100%

I. F. Project Team Accountability/Project Objectives (10) 10 10 100%I. G. Incident Reviews (10) 10 10 100%I. Project Planning Totals (95) 95 95 100%

2. Contractor Selection2. A. Contractor Safety Language and Addendums (30) 30 30 100%2. B. Bid Meeting & Bid Documents (10) 10 10 100%

2. C. Contractor Safety Prequalification Criteria (50) 50 50 100%2. Contractor Selection Totals (90) 90 90 100%

Section I. Planning and Contractor Selection Total (190) 185 185 100%

Section II. Contractor Safety Best Practice Execution: II. A. Project Premobilization Meetings (9) 9 9 100%II. B. Contractor Site Safety Plan (15) 15 15 100%

II. C. Contractor Orientation (21) 24 21 88%II. D. Cargill Contractor Safety Site Activity Requirements (78) 78 78 100%II. E. Contractor Safety Site Activity Requirements (42) 48 42 88%

Section II. Project Execution Total (165) 174 165 95%

Section III. Construction Site Safety InspectionIII. A. Excavations (15) 15 15 100%III. B. Crane Operations (21) 24 21 88%

III. C. Fall Protection (15) 12 12 100%III. D. Ladders & Scaffolds (18) 18 12 67%III. E. Vehicles / Mobile Equipment (18) 18 18 100%III. F. Hoisting & Lifting Equipment (6) 6 6 100%

III. G.Tools & Equipment (21) 21 21 100%III. H. Fire Protection (12) 15 12 80%III. I. Personal Protective Equipment (15) 15 12 80%III. J. Site Housekeeping (24) 24 20 83%III. K. Permits & Prejob Hazard Analysis (12) 9 12 133%

Section III. Site Safety Inspection Total (177) 177 161 91%

96%TOTAL CONSTRUCTION SAFETY AUDIT (AVERAGE SECTION I, II and III)

Contractor Safety Audit Form

Cargill Incorporated

Section I. Self Assessment-Project Planning and Contractor Selection:


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A. Zero Injury Expectations PP PA

1. Have Zero Injury expectations been established for this project and included in the following:

a. Project objectives and KRAs (4) 4 4

b. Bid documents and contracts. (4) 4 4

c. Project Communications. (4) 4 4

Total (12) 12 12

B. Project Safety Budgets PP PA

1. Has a formal construction safety budget been established for this project? (4) 4

2. What percentage of total project budget is set aside for project safety?Percent %

3. Is it clear that project safety budget is being used for project safety expenses and not itemsincluded in capital budget? (4) 4

Total (8) 8 0

C. Project Safety Staffing: Projects > $ 5 Million PP PA

If project is less than $ 5 million and proceed to section D.

1. For project over $ 5 million or projects with significant health and safety hazards, has a trainedCargill Contractor Safety Specialist (CSS) been assigned to the project or location and is stationedon site? (35) CSS

Name: 35 352. Have all Cargill project team members received Cargill 10-hour contractor safety training orequivalent? (5) 5

Total (40) 40 35

D. Project Safety Staffing: Projects < $ 5 Million PP PA

If project is $ 5 million or greater complete section C.

1. For smaller projects, where a CSS is not assigned has a safety representative been designatedwho has completed at least 10-hour construction training and is responsible for the implementationand monitoring of the project safety and health plan? (20)

10-Hour Trained Name:Alejandro Gutierres,Reynaldo Torres 202. For smaller projects, has a CSS been assigned to provide safety oversight? (10)CSS Name:Vanessa Arriaga T. 10

3. Does the CSS visit the site at least twice per month? (5)When was the last time the assigned CSS visited the site? Visit Date: 5

4. Have all Cargill project team members received Cargill 10-hour contractor safety training orequivalent? (5) 5

Total (40) 40 0

Section I Rating Instructions: Rating for this section's questions are scored as either fully implemented or not impleThere is no partial credit. The points possible of each question are in parethesis. Enter points possible under (PP) heEnter points awarded under (PA) heading.

Comments:

Comments:

Section I. Self Assessment-Project Planning and Contractor Selection:

1. Project Planning

Comments:

DRAFT 2/28/07 Cargill Confidential/Contractor Safety Audit-Planning & Contractor Selection Page 3


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E. Constructability Reviews PP PA

1. Are formal constructability reviews of this project completed and documented? (5) 5

2. As a result of constructability reviews, were any unique or best practice construction techniquesdeveloped or implemented? (5)

53. Has a master schedule with work breakdown/tasks been developed and tracked? (5) 5 5

Total (15) 15 5

F. Project Team Accountability/Project Objectives: PP PA

1. Are contractor safety metrics included in Key Results Areas for all project team members orproject engineers who routinely hire contractors? (4) 4

2. Do team member or project engineer Key Result Areas include the following:

a. Has zero accidents been established as an expectation? (2) 2 2

b. Contractor injury and illness rate? (2) 2 2

c. Are leading contractor safety metrics included? (2) 2 2Total (10) 10 6

G. Incident Reviews PP PA

1. Has a system been established to ensure business unit leadership involvement in any seriousinjury's), fatality (s), environmental incidents or major property loss? (10) 10 10

Total (10) 10 10

2. Contractor Selection:

A. Contractor Safety Language and Addendums: PP PA1. Does the project contract/purchase order include safety provisions which mandate compliancewith applicable laws and Cargill safety rules and regulations? (5) 5 5

2. For contracts over $250,000 has a contractor safety addendum been included as part of thecontract which addresses the following for the contractor and the contractor's subcontractors?

a. Zero Injury expectations (2) 2 2

b. Ensures compliance with applicable laws and Cargill Safety rules? (2) 2 2

c. Disciplinary policy for failure to follow safety rules? (2) 2 2

d. Contractor health and safety policy signed by CEO? (2) 2 2

e. Contractor safety personnel requirements and staffing? (2) 2 2

f. Minimum training for contractor/subcontractor employees? (2) 2 2

g. Premobilization meetings? (2) 2 2h. Development of site safety plans and major activity job safety analysis? (2) 2 2

i. Incident and safety statistic reporting requirements? (2) 2 2

j. Pre-job hazard analysis? (2) 2 2

3. Where allowed, have contractor drug and alcohol testing requirements been included in theproject contract? (5) 5 0

Total (30) 30 25

Comments:

Comments:

Comments:

Comments:

Comments:



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B. Bid Meeting and Bid Documents: PP PA

1. Contractor safety contract requirements/addendums, Cargill safety rules and any other technicalsafety standards are emphasized during all bid meetings and are included or referenced with all biddocuments and reviews? (10) 10 10

Total (10) 10 10

C. Contractor Safety Prequalification Criteria: PP PA

1. Has the location established safety prequalification criteria for all contractors and subcontractorswhich includes the following?

a. Injury and illness experience of the contractor? (5) 5

b. Contractor safety policy and programs? (5) 5

c. Past Cargill experience? (5) 5

2. Contractors are safety prequalified before allowing them to bid on projects? (15) 15 153. Does the site have a process to manage contractors who are approved by exception? (5)

4. Does site have a process to manage contractors who may have been placed on probation? (5) 55. Has the location implemented prequalification for sub-contractors ? (15) 15 15

Total (50) 50 30

Comments:

Comments:



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Section II. Contractor Safety Best Practice Execution:

A. Project Premobilization Meetings: PP PA N/A

1. Does the site conduct premobilization meeting with all contractors and their sub contractorsutilizing a pre-mobilization safety checklist for all projects > $ 1 million? (3) 3 3

2. Are findings from the premobilization meeting well documented with action registers? (3) 3 3

3. Are items listed on the action register being implemented? (3) 3 3

Total (9) 9 9

B. Contractor Site Safety Activity Plan: PP PA N/A

1. Have primary contractors developed a detailed Site Safety Activity Plan which details how thecontractor will manage all aspect of safety on the project? (3) 3 3

2. Have primary contractors developed fall prevention plans for all elevated work activity? (3) 3 3

3. Have primary contractors developed job safety analysis for all major activity to be conducted atthe site? (3) 3 3

4. Are these documents reviewed with a Cargill representative before the actual work is tocommence? (3) 3 2

5. Have primary contractors developed a detailed plan for managing their subcontractors? (3)

3 2

Total (15) 15 13

C. Contractor Orientation PP PA N/A

1. Has a Cargill site specific orientation program been developed which includes the following:

a. Site specific orientation provided to all contractor/subcontractor employees to insure Cargillsafety requirements and EHS policy are understood? (3) 3 3

b. Contractor/subcontractor employee attendance at training is documented and includescomprehension verification? (3) 3 2

c. Cargill representatives participate in delivering orientation? (3) 3 3

2. For sites with multilanguage issues has a process been established to insure site safetyorientation and safe work instruction is comprehended? (3) 3 3

3. A contractor site safety handbook is developed which summarizes Cargill site rules and EHSrequirements is provided at completion of training? (3) 3 0

4. Processes exist to verify that contractor/subcontractor employees have received necessary

certifications or other trade craft qualifications (e.g. electricians, crane operators etc. (3)3 3

5. Processes exist to verify that contractor subcontractor employees have received necessaryregulatory training (e.g. scaffold user training, hot work, etc.) ? (3)

3 3

Section II Rating Instructions: 0 = Not implemented or no system in place, 1 = System is only partially implemented andsignificant gaps exist, 2 = System is implemented with minor deficiencies, 3 = Fully implemented at the site, N/A Not

Applicable or Not Assessed.

Comments:

Comments:

Draft 9/30/06 Cargill Confidential/Contractor Safety Audit-Best Practice Execution Page 9


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6. 65% or greater contractor employees onsite have completed 10-hour construction safetytraining or equivalent? (3) 3 3

Total (24) 24 20

D. Cargill Contractor Safety Site Activity Requirements. PP PA N/A1. Control procedures are established to ensure only authorized personal have access to the sitewhich include daily attendance logs or equivalent methods to account for who is on site has beenestablished? (3) 3 3

2. Contractor/subcontractor injury and illness records are maintained on all contractors andreported to Cargill representative at least monthly? (3) 3 3

3. Incident reporting process has been established to insure that reportable injuries, significantnear misses, spills and property damage incidents are reported to a Cargill representativeimmediately? (3) 3 3

4. Root/basic cause analysis is implemented for all investigation? (3) 3 3

5. Evidence exists that an active near miss program has been implemented? (3) 3 3

6. Corrective action systems are established to ensure that all reports of substandard conditionsor behaviors, incident investigation recommendations or inspection findings are appropriatelytracked and addressed? (3) 3 3

7. A formal drug and alcohol testing program has been established where allowed? (3) 3 0

8. Cargill management is visibly supporting contractor safety by enforcing Cargill safetyrequirements during construction and contractor requirements? Including where appropriateimposing sanction on contractors for noncompliance with safety requirements? (3) 3 3

9. Cargill management is visibly active supporting contractor safety program by attending safetymeetings/toolbox meetings at least weekly? (3) 3 3

10. Cargill management has implemented Pre-job hazard planning (PJHA) for the site? (3) 3 3

11. Cargill management is visibly active supporting contractor safety by conducting both formaland informal inspections and/or observations? (3) 3 3

12. Cargill management has implemented a behavior observation process at the site which

includes the following:a. Formal observations conducted by trained observers? (3) 3 3

b. Measurement process to track percent safe and at-risk behaviors? (3) 3 3

c. Intervention process which target behaviors that need to be improve? (3) 3 3

13. A safety recognition process has been established for all contractors which include:

a. Recognition and incentives are provided based on milestones (e.g. 1 month no recordables).(3) 3 3

b. Recognition and incentives are based upon activity and positive performance? (3) 3 3

14. Contractor activity is considered in development of project or site emergency action planswhich include:

a. Emergency procedures including evacuation, assembly points and actions to be taken forforseeable emergencies? (3) 3 2

b. Have arrangements been made with the owner, ambulance service, hospital or others tohandle medical care ranging from first aid to life-threatening injuries or illness? (3) 3 1

c. Is contractor involved in location/project drills. (3) 3 N/A

15. Site/project contractor safety performance metrics and reports are prepared which include thefollowing:

a. Contractor safety and illness statistics? (3) 3 3

Comments:



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b. Proactive leading indicators (e.g. Near miss reports, observation results)? (3) 3 3

c. Project/site performance metrics are reported to BU leaders at least monthly? (3) 3 3

16. Information from safety meetings, incident lesson learned, inspection/behavior observationresults and site safety recognition is effectively communicated to all project personnel ? (3)

3 3

17. Cargill management periodically audit contractor safety programs to ensure appropriate

training and program documentation is available? (3) 3 3

18. Cargill and contractor policies, procedures and management system are updated toincorporate lessons and findings from measures, audits, and review ? (3) 3 3

19. Cargill management holds post project review meeting with contractor to review contractorsafety performance? At project end, good user practices and project management systems arecaptured and reinforced. (3) 3 3

Total (78) 78 69

E. Contractor Safety Site Activity Requirements. PP PA N/A

1. Contractor safety supervisor staffing at the site is as follows (including the sub contractors):

a. For contractors with < 30 employee, the contractor must have at least one supervisor on sitewho has completed 10-hour construction safety training or equivalent? (3)

3 N/A

b. For contractors with 30 or more employees, a full time safety supervisor is on site with 30-hour construction safety training or equivalent? (3) 3 3

c. For contractors with 60 or more employees, two full time safety supervisors are on site with 30-hour construction safety training or equivalent? (3) 3 N/A

2. Contractor retains appropriate training records at the site to verify their employees areappropriately trained and qualified to perform their assigned tasks? (3) 3 3

3. Does the contractor have a written disciplinary policy that addresses safety and healthviolations? Is it actively enforced? (3) 3 3

4. Does the contractor have a written safety policy, signed by the CEO/Owner at the site? (3)3 3

5. Does the contractor's management actively demonstrate support for improved safetyprograms? (3) 3 3

6. Contractor representative participates on all project safety/coordination meetings? (3) 3 3

7. Contractor holds safety/tool box meetings, at least weekly? Records available? (3) 3 3

8. Has contractor implemented prejob hazard assessment process (PJHAs)? (3) 3 3

9. Contractor conducts formal worksite safety inspections, at least weekly? (3) 3 3

a. Are inspection records/reports available? (3) 3 3

b. Are inspection issues addressed promptly and documented? (3) 3 3

10. Formal housekeeping inspection program is established and housekeeping status revieweddaily? (3) 3 2

11. Has the contractor established a formal recognition process for his employees and

subcontractors? Is it effective? (3) 3 212. For multiple language sites, have language issue been addressed effectively? (3)

3 3

Total (48) 48 40 83%

Comments:

Comments:



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Section III. Construction Site Safety Inspection:

A. Excavations: PP PA N/A

1. Geotechnical reviews of soils of excavations completed? (3) 3

2. Are excavations controlled through prejob plan or permit? Inspected daily by competentperson? (3) 3 1

3. Are all excavation sloped and shored correctly? (3) 3 3

4. Access and egress provided every 25 ft (8 m)? (3) 3 N/A

5. Edge protected and spoil pile maintained at lease 3 ft (1 m) from edge? (3) 3 3

Total (15) 15 7

B. Crane Operations: PP PA N/A

1. Crane operator training/qualification documentation available? (3) 3 3

2. Rigging/lift study plans have been developed and approved by Cargill representative? (3) 3 0

3. Annual crane certification documentation is available at the site?(3) 3 34. Crane load/rate charts and operating manuals are availabe in the crane? (3) 3 2

5. Daily preuse and inspectons are completed and available in the crane? (3) 3 3

6. Inspections of rigging prior to each use? (3) 3 3

7. Crane operation, guarding and clearances are appropriate? (3) 3 3

8. Crane suspended personnel platfroms used appropriately? (3) 3 3

Total (21) 24 20

C. Fall Protection: PP PA N/A

1. Approved body harness and lanyard required and worn in a proper manner? (3) 3 3

2. Lanyards are adequatey secured to suitable anchorage? (3) 3 2

3. Perimeter guarding (e.g. rail systems) installed for all open floor/work surfaces? (3) N/A4. Horizontal and vertical life lines installed properly and capable of supporting 5,000 lb(2,200kg) per person of force? (3) 3 2

5. Fall protection maintained and has current inspection? (3) 3 3

Total (15) 12 10

D. Ladders and Scaffolds: PP PA N/A

1. All scaffolding is appropriately built by a competent person? (3) 3 1

2. Proper access and egress provided to scaffolding? (3) 3 2

3. Are all scaffolds inspected daily by competent person and appropriately tagged? (3) 3 2

4. All scaffold users are trained? (3) 3 35. Proper ladders for the job are provided?(3) 3 1

6. Ladders used at appropriate angles, secured and exceed landing by 3 ft (1 m)? (3) 3 2

Total (18) 18 11

Comments: Numbers of lifelines are not sufficient for workers to work.

Comments: Most of the scaffoldings and ladders are homemade ones, these scaffolds were inspected weekly.

Section III Rating Instructions: 0 = Not implemented or no system in place, 1 = System is only partially implemented and significantgaps exist, 2 = System is implemented with minor deficiencies, 3 = Fully implemented at the site, N/A Not Applicable or NotAssessed.

Comments: Excavations are controled, but w/o daily inspection.

Comments: Crane load chart is accessible at site, but the manuals are not available. Riggings are checked by

Adonis before performing job, but not formal study.

Draft 2/28/07 Cargill Confidential/Contractor Safety Audit-Site Inspection Page 12


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E. Vehicles / Mobile Equipment: PP PA N/A

1. Vehicle operator training/qualification documentation available? (3) 3 3

2. Daily preuse and inspectons are completed and available in the vehicle? (3) 3 3

3. Equipment is properly maintained? (3) 3 3

4. Seat belts provided and used? (3) 3 0

5. Equipment operated safely? (3) 3 3

6. Back-up alarms installed and tested regularly. On site, back-up alarms in operation.(3)3 3

Total (18) 18 15

F. Hoisting and Lifting Equipment: PP PA N/A

1. Chainfalls, slings and chokers in good condition with current inspection and working loadlimit tags in place? (3) 3 3

2. Softeners used as required? (3) N/A

3. Proper rigging techniques used? Trained rigger? (3) 3 3

Total (6) 6 6

G. Tools and Equipment: PP PA N/A

1. Electrical cords - condition and current inspection? (3) 3 3

2. Ground fault interrupters used where needed? (3) N/A

3. Tools are maintained and in safe condition? (3) 3 3

4. Tools are properly carried and stored? (3) 3 35. Pneumatic/hydraulic hose connections properly secured? Hoses in good repair? (3) 3 3

6. Proper tools for the job performed? (3) 3 3

7. Power activated tools used safely? (3) 3 3

8. Proper guards on saws and grinders. (3) 3 3

Total (21) 21 21

H. Fire Protection: PP PA N/A

1. Flammables stored properly? (3) 3 1

2. Oxygen and combustible material stored seperately? (3) 3 3

3. All containers labeled with content? (3) 3 3

4. Fire extinguishers properly located and inspected? (3) 3 3

5. Welding equipment and cylinders well maintained? (3) 3 3

Total (15) 15 13

I. Personal Protective Equipment: PP PA N/A1. Hard hats worn and maintained as required? (3) 3 3

2. Hearing protection worn as required? (3) 3 3

3. Eye protection (Glasses, face shields or googles) worn/maintained as required? (3) 3 3

4. Appropriate foot protection worn and maintained as required? (3) 3 3

5. Other protection(Respirators, gloves and chemical clothing) worn as required ? (3) 3 3

Total (15) 15 15

Comments: Almost all of our vehicles don't have any seat belt, but we use body harness if the working height

is more than 1.2m.

Comments:

Comments:

Comments: Most of material are labelled, but some of them are hardly to distinguish due to wearness.



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J. Site Housekeeping: PP PA N/A

1. Project work areas are clean and free of excess trash and debris? (3) 3 3

2. Passage ways and walkways kept clear? (3) 3 1

3. Material and equipment properly stored and ready for use? (3) 3 3

4. Electrical cords, welding leads etc. elevated to prevent trip hazards? (3) 3 3

5. Scrap material free of protruding nails or other puncture hazards. (3) 3 3

6. Trash recepticles available and maintained? (3) 3 0

7. Barricades and/or rebar caps installed and maintained? (3) 3 2

8. Oils and other chemical properly stored with not evidence of spills (3) 3 3

Total (24) 24 18

K. Permits and Prejob Hazard Analysis: PP PA N/A

1. Applicable permits posted and properly executed? (3) 3 3

2. Pre-job hazard analysis and job pre-talk completed and available at the site? (3) 3 3

3. Are appropriate job procedures being followed? (3) 3 3

4. Material Safety Data Sheets availabe for all chemicals on site (3) N/A

Total (12) 9

TOTAL 177 136 77%

Comments: For rebars we don't have rebar caps, but we use cardboard for protection. Trash recepticles are

not available at site too.

Comments:


Safety Audit Feb 3 2010

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Transcript of Safety Audit Feb 3 2010