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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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• Demand for full information and for public involvement

• A willingness to challenge and complain

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Corporate Strategy

• Business Mission, Philosophy and codes of ethics• Company image in the community• Environment impact• Management Professionalism

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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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Human Resources

• Work and job structuring• Morale and retaining people• Positive health structure

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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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Organizations carry out

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

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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

MONITORING

• COMPARE ACTUAL PERFORMANCE -STANDARDS

• COMPREHENSIVE

• CONTINUOS

AUDIT

• NOT DONE BY INSIDER

• NOT COMPREHENSIVE-DEPENDS ON SCOPE

• PERIODIC

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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

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Hardware Software

Humanware

Safety Depends on

•Engineering

•Procurement

•Maintenance

•Accident and incident analysis

•Work permit

•Health and Hygiene

•Emergency

•PPE

•Leadership

•Task observation

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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 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.

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• EXPANSION MODIFICATION -AUTHORIZATION PROCEDURES.

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

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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

Wayne Pardy, CRSPwww.cholaaxa.com

Safety Leadership is key to success

Survey by Linkage, inc., 1999

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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 choiceboth ON and OFF the job

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Safety and Incident PreventionSafety and Incident Prevention

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

AATTTTIITTUUDDEE

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