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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 systems 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 companys 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 Survey: Detailed examination of a narrower field of activity-e.g.- key areas revealed by safety audits
Safety Inspection: Routine inspection-work is being carried in accordance with procedures etc. Safety Tour: Unscheduled examination-hazards are removed-standards are removed
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Safety 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 COMPREHENSIVEDEPENDS 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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Safety Depends on
Engineering

Work permit

Accident and incident analysis

Emergency
Procurement

Hardware

Software

Humanware
Leadership PPE Health and Hygiene Task www.cholaaxa.com 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.

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AUDIT
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 PROCEDURESDEGRADED 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 www.cholaaxa.com

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 www.cholaaxa.com Record of montioring 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 www.cholaaxa.com

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, www.cholaaxa.com Transportation of Hazardous substances

TOPICS ON WHICH INFORMATION IS COLLECTED


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
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Safety Leadership is key to success

Wayne Pardy, CRSPwww.cholaaxa.com Survey by Linkage, inc., 1999

Safety Culture
Liveware

Safety Culture
Hardware Software

Acts-Practice-Habit-Behavior-Culture
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Coincident or Not ?
If, ABC D EFGHI J K L M N O PQ 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+E 11 + 14 + 15 + 23 + 12 + 5 + 4 + 7 + 5 = 96%

H+A+R +D+W+ O+ R +K 8 + 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+E 1 + 20 + 20 + 9 + 20 + 21 + 4 + 5 = 100%

Safety really is about attitude. Make 100% Safe Behavior your choice www.cholaaxa.com both ON and OFF the job

Safety and Incident Prevention


Depends how much on ATTITUDE ?
A T T I T U D E = = = = = = = = 1 20 20 9 20 21 4 5

100%

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