THE TLC COMPANIES Self Inspection Program Self Inspection Program
Table of Contents SECTION 1 INSPECTION REQUIREMENTS 1 Informal Inspection 1 General Inspection 1 SECTION 3 CONDUCTING INSPECTIONS 5 Preparation 5 Safety Checklist 7 Inspection Report Summary 13 SECTION 2 Safety Recommendation Form 15 INSPECTION RESPONSIBILITIES 3 Safety Coordinator 3 Plant Management 3 First Line Supervisor 3 Maintenance 4 Employees 4 Outside Inspectors 4 Contractors Inspection Services 4 Revised 12/13/2002
SELF INSPECTION PROGRAM Section 1 Self Inspection Program T he basic purpose of conducting an inspection of the workplace and equipment is to detect potential hazards so they can be corrected prior to an accident occurring. A thorough inspection can determine those conditions, which need to corrected or improved to bring operations up to acceptable standards, both from safety and operational standpoints. Inspection Requirements INFORMAL INSPECTION It is expected that a continuous or informal inspection will be conducted by employees, foremen, supervisors, and maintenance personnel as part of their job safety responsibilities (See Section Page ). This informal inspection involves noting an apparently or potentially hazardous condition or unsafe act and either correcting it immediately or making a report (utilizing Safety Recommendation Report) to the Safety Coordinator to initiate corrective action.! GENERAL INSPECTION A general inspection of each facility will be conducted by the Safety Coordinator and other appointees as required on a monthly basis in conjunction with the safety committee meeting. A general inspection will cover all areas of the facility, including areas where no on ever goes. It is advisable to schedule the inspections when maximum observations can be made with the least amount of work interruption. The inspection team should be limited in size to approximately two to four members. These should represent production, supervision, and safety. The team will be under the direction of the Safety Coordinator who will provide the authority 1
SELF INSPECTION PROGRAM necessary to assure its effectiveness. Specific responsibilities should be assigned within the team (i.e., who will take notes, be the spokes person, follow-up on recommendations, etc.). Accurate inspection records are important. They serve as evidence of the program, provide documentation of necessary corrective actions and provide a method of follow up to insure completion. The following checklist has been developed to serve as a guide in your inspection process and can be tailored to meet facility needs. 2
SELF INSPECTION PROGRAM Section 2 Inspection Responsibilities " SAFETY COORDINATOR During both individual and group inspections, this individual can perform an educational function. By using on the spot examples and first hand contact, supervisors, foreman, and employees can be taught the fundamentals of hazard identification. The safety coordinator will head the self-inspection program to insure that its followed. They will be responsible for recommendation follow-up and record keeping requirements. PLANT MANAGEMENT Safety inspection should be considered part of the duties of plant management. By participating in inspections, management evidences its commitment to assuring a safe working environment. Management should participate in the inspection process on a bi-annual basis at a minimum. FIRST LINE SUPERVISOR At least once a day, supervisors need to check their areas to see that: (1) employees are complying with safety regulations; (2) guards and warning signs are in place; (3) tools and machinery are in a safe condition; (4) aisles and passageways are clear and proper clearances are maintained; and (5) material in process is properly stacked or stored. A supervisor also should conduct regular inspections make certain all hazards have been detected and safeguards are in use. 3
SELF INSPECTION PROGRAM MAINTENANCE Either as individuals or as members of the safety committee, the maintenance superintendents need to conduct regular inspections of their work area and of equipment in the facility. Necessary work orders for guards or for correcting faulty equipment can be written up on the spot. EMPLOYEES Before beginning the work day, the employees should inspect the workplace and any tools, equipment, and machinery that will be used. Any defects the employee is not authorized to correct should immediately be reported to the supervisor. OUTSIDE INSPECTORS Sometimes are required or needed to perform general inspections. These may include for example, insurance company safety engineers, and local, state, and federal inspectors. CONTRACTORS INSPECTION SERVICES For some technical systems, notable sprinkler systems, contractors companies furnish inspection services. Other items outside contractors may inspect and maintain include fire extinguishers, hoses, fire doors, conveyers, hoists, etc. The contractor should provide a comprehensive written report. The basic contract may not include maintenance work or materials required for alterations, repairs, or replacement. However, if the report indicates any maintenance needs, the facility can have the contractor perform the work. 4
SELF INSPECTION PROGRAM Section 3 Conducting Inspections # PREPARATION Prior to conducting the inspection, consideration must be given to the following: 1. Training of inexperienced team members must be conducted. Such areas as plant lay out and production flow; standards, regulations, and codes; hazard recognition of unsafe acts and conditions; and the purpose of the inspection should be covered. 2. Previous inspections should be reviewed. This is to insure that previous recommendations have been completed. 3. Accident records for the various areas or departments should be reviewed. Information concerning how a particular accident occurred often will reveal hazards which need to be corrected. 4. All necessary personal protective equipment should be provided and worn in areas where it is required. 5. A pre-planned route should be developed. This will insure that all areas will be inspected completely and thoroughly. This will also eliminate backtracking, unnecessary interruptions of production processes and distractions. Inspectors should locate and describe each hazard found during the inspection. A clear description of the hazard should be addressed in the comment/action section of the inspection report. It is important to note which hazards present the most serious consequences and are most likely to occur. Unsafe conditions or deviations from accepted practices must be described in detail. Machines and operations must be identified by their correct names. Locations must be accurately named or numbered. Specified hazards must be described. 5
SELF INSPECTION PROGRAM When a piece of equipment presents an imminent danger, the inspector should notify the supervisor and see to it that the machine or equipment is shut down, tagged, or locked out to prevent its further use. No equipment or materials should be placed out of service without notifying the person in authority in the department affected. A written report summarizing the results of the inspection needs to be made. A sample inspection summary report follows. This report should include the date and time of the inspection, names of those performing the inspection, date of the report, and the names of those to whom the report was made. When the inspection report is written and disseminated, the inspection process starts to return benefits. The information acquired and the recommendations made are without value unless corrective action is taken. Information and recommendations provide the basis for establishing priorities and implementing programs that will reduce accidents, improve condition, raise morale,. and increase the efficiency and effectiveness of the operation. $ Recommendations can be listed in the order in which the hazards were discovered or grouped according to the individual responsible for their compliance. Recommendations should then be sent to the proper persons for implementation and approval. Where possible, a definite time, the results of the inspections should prompt actions to correct identified problems. The following guidelines should be utilized: 1. Correct the cause of the problem when ever possible. If the authority needed is above the inspector's, make certain that it is brought to the attention of an individual who has the proper authority. 2. When authority exists to correct or minimize a problem or hazard, do it immediately. 3. Conditions that cannot be corrected immediately should be conveyed to management in a written report. The condition should be listed in the order of priority, including suggested solutions and compliance dates, if possible. 4. Management should advise the inspectors as to what actions are planned on the suggestion, or the reasons why actions will not be taken. A time limit for compliance should be set for each recommendation, and followed up. 6
Safety Checklist Faculty: Inspected By: Date: AREAS TO BE INSPECTED: N/A YES NO COMMENTS/ACTIONS BUILDING AND PREMISES Walking-Working Surfaces 1. Are walkways properly marked and cleared? 2. Are exterior walkways cleared and in good repair? 3. Are floor holes, floor openings, wall openings, and skylights guarded? 4. Are gratings, non-skid mats, or other non-slip materials used in wet areas? 5. Are gratings, mates, etc., in good repair? 6. Are hatch ways, manholes, etc., protected with adequate covers? 7. Are open-side floors, platforms, and runways which are four feet or more above ground level, guarded and provided with toeboards? 8. Do railways and toeboards meet standards and are they in good repair? 9. Are elevated load bearing floors and roofs posted with safe load limit signs? Illumination 1. Is lighting in work and storage areas adequate? 2. Is lighting in non-work areas adequate? 3. Are emergency and explosion-proof lighting systems adequate? 4. Is temporary lighting adequate and properly guarded? 7
AREAS TO BE INSPECTED: N/A YES NO COMMENTS/ACTIONS Stairs and Stairways 1. Are stairs, elevator landings, and escalators clear and in good repair? 2. Are handrails and guardrails adequate and surfaces non- slippery? Ladders and Scaffolds 1. Are ladders equipped with safety feet? 2. Are ladders in good condition? 3. Are precautions taken not to use metal ladders if there is an electric shock exposure? Ventilation 1. Any accumulation of smoke, fumes, or dust? 2. Is the temperature and the air movement in work areas satisfactory? Life Safety 1. Are there at least two fire emergency exits for each work area and are they easily accessible? 2. Are exits properly marked and illuminated? 3. Is exit route clear and unobstructed? 4. Do exit doors open in direction of exit? 5. Are exit doors equipped with panic hardware and no other locks? Fire Suppression Equipment 1. Are portable extinguishers properly located? 2. Are extinguishers tagged and their service up-to-date? 3. Are extinguisher located within 75 feet travel distance? 4. Is proper extinguishing equipment available for all areas? 5. Is an 18 inch clearance maintained between sprinklers and the top of stored materials? 8
AREAS TO BE INSPECTED: N/A YES NO COMMENTS/ACTIONS Electrical 1. Are extension cords and temporary wiring free from breaks and defects? 2. Assured equipment or grounding conductor program in affect? 3. Are outlet boxes provided with adequate covers? 4. Are electric hand tool cables in good condition? Boilers, Heating & Cooling 1. Is the boiler room clean and is ventilation adequate? 2. Is boiler room fire door kept closed? Sanitation 1. Are dressing rooms clean? 2. Is the lavatory area clean? 3. Are waste receptacles adequate? 4. Is the lunch room clean? 5. Are vending machine areas clean? First Aid 1. First Aid kits available and properly stocked? 2. Is there a trained first aider available on all shifts? 3. Emergency phone numbers posted? EQUIPMENT AND OPERATIONS Material Handling 1. Are hoists in good condition and servicing records up-to-date? 2. Do chains have current inspection tags? 3. Are records available of tests on all hooks and rings in service? 4. Are warning devices on industrial trucks working? 5. Are there overhead guards on all industrial trucks? 6. Are industrial trucks being fueled in a safe area? 7. During refueling is engine stopped and is "NO SMOKING" rule observed? 9
AREAS TO BE INSPECTED: N/A YES NO COMMENTS/ACTIONS 8. Is ventilation adequate in battery recharging areas? 9. Is a fire extinguisher in working order on each industrial truck? 10. Is the load capacity indicated on each industrial truck? 11. Carts in good condition? 12. Are conveyor systems in good operating condition? Hand and Power Tools 1. Are hand and potable power tools in good condition? 2. Are tools equipped with grounds and is wiring satisfactory? 3. Are guards in good condition and adequate? 4. Is compressed air used for cleaning regulated to 30 psi maximum? 5. Is chip guarding and personal protective equipment provided for air cleaning? 6. Are impact tools in good condition? Machine Guarding 1. Is the point of operation guarded? 2. Pulley belt assemblies guarded? 3. Gear assemblies guarded? 4. Shafts guarded? 5. Are there any oil leaks? 6. Two hand controls working properly? 7. Lockout/Tagout policy in force? Material Storage 1. Are materials stored so as to create a fire or safety hazard to employee? 2. Is material storage on the exterior of building at least 15 feet from the building? 3. Is storage properly stacked and secured? 4. Where hazardous materials are stored is the area fire safe and restricted? 10 Revised 05/01
AREAS TO BE INSPECTED: N/A YES NO COMMENTS/ACTIONS 5. Gases, liquids, etc., properly labeled and stored? Finishing Operations 1. Are spray finishing facilities properly shielded and ventilated, and is approved explosive atmosphere electrical equipment used? 2. Is spray booth in good condition and free of paint accumulation? Personal Protective Equipment 1. Is protective equipment in use where required? 2. Is protective equipment in good condition? Welding, Cutting, and Brazing 1. Are compressed gases properly stored? 2. Are welding operations properly screened? 3. Cylinders mounted on a cart or secured in an upright position when in use? 4. Gas hoses and gauges in good condition? ENVIRONMENTAL CONTROLS Noise 1. Is protective equipment being worn where required? 2. Does the noise level seem too high in any of the work areas? Dust, Fumes 1. Are there any areas or operations that have dust or fume emissions? 2. Is air dusty or vision obscured by haze? Vapors, Gases 1. Are there any areas or operation where you believe excessive vapors or gases exist? 2. Any odors noticed? Liquids 1. Any accumulation of process compounds that constitute a hazard? 11
AREAS TO BE INSPECTED: N/A YES NO COMMENTS/ACTIONS 2. Any evidence of excessive vapors or mists? Exhaust Ventilation 1. Do ventilation systems appear to be free of obstructions, damaged or missing piping? 12
Inspection Report Summary Area Inspected: Inspector and Title: Date and Time of Inspection: Date of Report: Names of Those to Whom Report is Sent: Number of Items Carried Over: Number of Items Added: Total Number of Items From Previous Report: To this Report: On This Report: Item (Asterisk Indicates Old Item) Hazard Description Specific Location Supervisor Corrective Action Recommended Corrective Action Taken 13
Item (Asterisk Indicates Old Item) Hazard Description Specific Location Supervisor Corrective Action Recommended Corrective Action Taken 14
Safety Recommendation Date Issued: Date Returned: To: PLEASE HAVE THE FOLLOWING UNSAFE CONDITION OR DEVIATION FROM STANDARD PROCEDURE CORRECTED: Please sign and return to the Safety Coordinator within ten days, indicating below what disposition was made of this recommendation. Safety Committee Recommendation Followed ( ) Work Completed Date Recommendation Rejected ( ) For Following Reason: Department Supervisor 15
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