Beruflich Dokumente
Kultur Dokumente
1
TOOLS TO BE ADOPTED
SAFETY AUDIT
SAFETY TRAINING
TESTING OF CRITICAL EQUIPMENTS
CONTRACTORS REGULATION
PRE-COMMISSIONING INSPECTION
MOTIVATION
ACCIDENT INVESTIGATION
FREQUENCY RATE / SEVERITY RATE
LAYOUT
EMPLOYEE PARTICIPATION
EMERGENCY PREPAREDNESS
LEGAL REQUIREMENTS
FIRE SAFETY
CHEMICAL HANDLING
COMMUNICATION
PERFORMANCE MEASUREMENT
COMMITTEE MEETING
ACCIDENT REPORTING
WORK PERMIT SYSTEM
ELECTRICAL SAFETY
WORK PLACE HYGEINE 2
FAMILY PARTICIPATION
ACHIEVING ZERO ACCIDENT THROUGH
SAFETY AUDIT
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SAFETY AUDIT
Foreword :
Purpose :
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SAFETY AUDIT
Evaluation of Safety performance :
•Overall checklist may not have the details
•Specific area (eg., material handling ) must have
detailed checkpoints
•Auditors with overall checklist with broad headings
should be trained in as a whole
•Auditors should rate the department in 1 to 10 scale
where 1 is poor and 10 is excellent.
•Scores may be displayed in a board in the unit to
propogate
•Record of non-conformities observed must be
discussed in the committee meeting to arrive at a
solution
•Re-audit should start with the status of the previous8
audit non-conformities
SAFETY AUDIT
Methodology
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SAFETY AUDIT
Methodology
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SAFETY AUDIT
Machine guarding checklist should contain the following :
• Is there any mechanical damage to the guarding ?
• Is machine running without guard exposing any potential
hazards ?
• Is guard designed and fixed inadequately ?
• Are doors and panels open ?
• Observed any guards placed on unwanted locations ?
• Are the trip guards functioning well ?
• Are the automatic guard limit switches functioning ?
•Are there any guards intentionally removed from m/c ?
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Furnace lid guarded 12
Additional / accurate Stopper to avoid over-ride of tilting furnace
13
Base of the furnace tilting furnace tied with chains to avoid toppling
14
Rigid guard provided to avoid injury to the abdomen 15
Pedestal fans provided with mesh 16
Machine guard removed from machine
Large gap between guards which gives access for burr flying
Large gap in between moving parts which will cause sever finger injur
Evidence of operating the drilling machine with gloves in hands,
which will lead serious hand injury
Protrusion of allen screw in revolving spindle,
which will cause for hand injury
Open rear side of a machine
Properly guarded ( painted in zebra, and interlocked)machine
Point of operation provided with a fixed guard,
to prevent finger injury
One of the doors open while operation due to malfunction
of trip switches
Evidence of poor maintenance of safe switches - Gear shift rod
tied with string
Large gap in between moving parts which will cause sever finger injur
Heavy tool on the loader which may slip while high rotating speed
Machine provided with guard but not adhered
Accumulation of loose cloth near revolving machine
Evidence of poor maintenance of safe switches - Gear shift rod
tied with string
SAFETY AUDIT
Safety switches :
1. Two hand switches
2. Trip switches
3. Emergency switches
4. Automatic guard limit switches
5. On / Off switches
6. Hand control valves (Air / Hydraulic
7. Foot pedal switches
8. Pull - cord switches
9. Proximity switches
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SAFETY AUDIT
Safety Switches checklist should contain the following :
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Correct design of
Two hand switch
And guard
35
Wrong method of
Operation posing fo
injury
36
Correct method of
Operation with
Two hand switches
37
Properly located flush type switch for cycle-on and mushroom
headed switch for emergency stop
Unsafe locations of valves which may cause hand injury
due to running spindles
Mushroom headed switches gives access for accidental touch
which may cause fro hand injury
Wrong method of operation under a tilting loader 41
Correct method away from the loader 42
Two hand switch in the core making machine
43
Not only the front side but also the rear side gap will cause
finger injuries
Collar provided to avoid rear side finger injury 45
Safe Limit Switch damaged
Unsafe locations of valves which may cause hand injury
due to accidental touch
Two-hand switches gap giving access to operate by thumb
and little fingers of one hand
Unsafe locations of valves which may cause hand injury
due to running spindles
Mushroom headed switches gives access for accidental touch
which may cause fro hand injury
SAFETY AUDIT
Layout of work place checklist should contain following :
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Adequate space around the machine
52
Adequate space around the machine
Caution display provided
53
A see-through spacing before all Electrical panels 54
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Ladder with all safety parameters – rails / treads / angle / footing
Good gangway marking and locators but unsafe stacking
SAFETY AUDIT
Material handling equipments checklist should contain
the following :
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High pressure air line connected to the fragile FRL unit which
leads to explosion
Extractor screw broken and not reconditioned
No toe-board to avoid falling of components in the trolleys
SAFETY AUDIT
Fire fighting equipment checklist should contain
the following :
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Arrangement of fire fire fighting equipments 69
LPG Safety – damaged hoses 70
LPG Safety – mishandled cylinders 71
Spillage of oil – potential for fire
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Layout of FFEs 74
Evidence of using paper as lighter
75
Fire extinguisers placed in an inaccessible place
SAFETY AUDIT
Training and knowledge checklist should express
the following :
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Training
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Training
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Training- First aid – family participation 80
Training- First aid – family participation
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Training
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SAFETY AUDIT
Chemical handling checklist should express
the following :
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Communication 89
Communication
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Convex mirror at the intersection of roads - communication
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SAFETY AUDIT
Storage of materials checklist should express the following :
•Are the incompatible materials stored near any
flammable substances ?
•Are the materials stored unsafely beyond the height
of 6 feet ? If so, what safety measure has been taken
•Are the highly flammable liquids stored in a closed
containers ? Are they away from heat source ?
•Are the chemicals stored in non-corrossive
containers ?
•Are adequate steps taken for controlling fumes ?
•Are the gas cylinders stored in the designated place
•Are sharp edges and pin points are protected ?
•Are the trays and stands are rigidly fixed to the
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ground ?
SAFETY AUDIT
Work environment hazards identification checklist should
express the following :
•Is there any complaint of unbearable noise ?
•Is there any complaint of unbearable temparature
• Is there any toxic emission ?
•Is there any fumes from the furnaces ?
•Is there any report of unbearable skin problems due
to chemical handling ?
•Can you find out which machine / operation /
chemical creates the hazard ?
•Is there any complaint of inadequate / overlighting
•Is there any complaint of ventilation / exhaust
•Do you find any evidence of countermeasure ?
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SAFETY AUDIT
Electrical safety checklist should express
the following :
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SAFETY AUDIT
Accident reporting checklist should express the
following :
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