Is your safety audit process stale with the organization's business plan? Avoid the common pitfalls that derail most safety audits. Identify policies and conditions that cause loss and incidents with the examples here in this presentation. Build the necessary elements of the written audit document. Author John Newquist has worked with several of the Fortune 500 companies in auditing safety management systems and best practices to prevent injuries and losses for the last 30 years. This was one session presented in a day long seminar in June 2013.

1. Elements of an Effective Safety
Audit System
Module 2
Johnanewquist@gmail.com
815-354-6853
Draft 5 27 2013

2. 4 Elements to Audit
• Management Leadership and Employee Involvement
• Worksite Analysis
• Hazard Prevention and Control
• Safety and Health Training
Effective Safety and Health Management System

3. Top 30 Company Audit (VPP)
Element Element Name # Questions Auditor Name
1 Site Health and Safety Policy 5
2 H&S Expectations & Performance Appraisals 9
3 Hazard Analysis and Regulatory Compliance 16
4 Employee Involvement 18
5 Health and Safety Specialist 7
6 Accident Reporting, Investigation and Follow-up 24
7 Health and Safety Training 12
8 Health and Safety Housekeeping and Inspections 20
9 Personal Protective Equipment 20
10 Contractor Safety 33
11 Emergency Preparedness and Fire Prevention 22
12 Safety Risk Assessment (JSA) 22
13 High Risk Operations 38
14 Management of Change and Preventive Maintenance 18
15 Industrial Hygiene 46
16 Chemical Management 35
17 Ergonomics 34
18 Motor Vehicle Safety 28
19 Medical Services 52
20 Program Evaluation 7
21 Lock Out Tag Out (LOTO) 35

4. Top 30 Site Safety Policy Audit
• Is there a written Health & Safety
policy, signed by the current
operation business leader(s)?
• Is the written policy readily
available and communicated to
all employees?
• Does the written Health & Safety
Policy assign responsibilities to
employees and all levels of
management?
• Are Health & Safety
measurements incorporated into
the operation business metrics?
• Can employees describe the
safety and health objectives for
the worksite?
• EHS I&I < 0.8
• Audit Ready with a closure rate >=
95%
• Promote active participation
amongst staff (75% or greater on
teams)

5. VPP Company Expectations
Examples of H&S Management
expectations include
• attending H&S training,
• conducting accident
investigations,
• conducting inspections,
• closing action items,
• performing safety observations,
• using proper work practices,
• reporting unsafe conditions
immediately, and
• wearing proper PPE.
• verify through document review
and employee interviews.

6. Insurance Trust Quarterly Audit

7. Ergo Audit Element
• A. Have you identified and
listed three ergonomic hazards?
• B. List ergonomic corrective
actions within last 12 months
• C. If you have had claims with
the root cause of ergonomics,
were corrective measures taken?
• D. Annual documented
training on ergonomics (back
safety, preventing hand fatigue,
material handling) for all
employees based on claim
history. Is an outline or
explanation of training available?
• E. Are there material handling
procedures implemented with a
maximum single-person lift capacity?
• Where posted:

8. Insurance Trust Results
• 0.84 EMR
• ~20% members had no
work comp claims in
2012
• 42% loss ratio vs. Ind
Avg 60%
• ~50% of members had
audit score of 90%

9. 4 Elements to Audit
• Management Leadership and Employee Involvement
• Worksite Analysis
• Hazard Prevention and Control
• Safety and Health Training
Effective Safety and Health Management System

10. Employee Participation
• Daily pre-job briefings
• Daily Morning Action
Plan (MAP) meetings
and
• Operation Hazard
Analyses (OHA),
• Stop Think Review
• Complete audits by ipad
or other tablets
Fire protection audits should be
performed on buildings under
construction.

11. Large Partnership Company
• 1600 near misses and hazards brought up by
employees in 6 plants.
• Employees look out for each other
• Incentives focus on leading indicators
• This is what you want!
• Employees bringing up safety, production, quality,
property, environmental and customer service issues.
• Use their experiences, eyes and ears.

12. OFI = Good Catch
• Any hazard or unsafe condition is a $20 gas
card.
• Recognized at monthly safety meeting
• 2,000 Good Catches in 4 years
• 1,000 employees
• 2008 TCIR 1.21 to 0.72 to 0.56
• 2.1 million hours = 0.28 incident rate in 2011

13. Find and Fix Action Cards
• Employees are encouraged to submit their
concerns on “Find and Fix Action Cards” to
resolve any safety or health issues.
• OH VPP site
• 345 Actions Cards in last 18 months.
• ~1000 total since 2008-2012.

14. Global Risk
Pyramid
Catastrophic
Multiple Fatality
Fatality
Serious Injury (M)
Minor Injury
Property Damage
Close Call
Behavior
Effort
Free lessons

15. 4 Elements to Audit
• Management Leadership and Employee Involvement
• Worksite Analysis
• Hazard Prevention and Control
• Safety and Health Training
Effective Safety and Health Management System

16. Safety and Health Training Auditing
• What do you train on?
• Is there a training
completion goal?
• How do you handle
missed training?

17. Region V Safety & Health Chapters
• Chapter 1 – Introduction
• Chapter 2 – Safety and Health Management
System
• Chapter 3 – Safety and Health
Metrics/Tracking
• Chapter 4 – Regional Office
• Chapter 5 – Area Office
• Chapter 6 - Office Safety and Health
• Chapter 7 - Emergency Contingency Plan
• Chapter 8 - PPE
• Chapter 9 - Vehicular Operations
• Chapter 10 - Violence in the Workplace
• Chapter 11 - Walking/Working Surfaces
• Chapter 12 - Hazard Communication
• Chapter 13 - Control of Hazardous Energy
Sources
• Chapter 14 - Permit Required Confined
Spaces
• Chapter 15 - First Aid & CPR
• Chapter 16 - Hearing Conservation
Program
• Chapter 17 - Fall Protection
• Chapter 18 - Respiratory Protection
• Chapter 19 - Bloodborne Pathogens
• Chapter 20 - Ergonomics
• Chapter 21 - Radiation
• Chapter 22 - Electrical Safety
• Chapter 23 - Protection During Incident
Investigation
• Chapter 24 - Employee Assistance
• Chapter 25 - Medical Management
• Chapter 26 - Decontamination
• Chapter 27 – Policy and Procedures for
Field Staff Exposure

18. Sample Training Audit Measures
• Annual Audit.
• Percent completion of
mandatory training;
• Percent completion of
annual physicals;
• Percent completion of
respirator fit tests;
• Percent completion of
required annual exercises
(such as Continuity Of
Operations Plan, Shelter In
Place Plan, Emergency
Action Plan etc.)

19. Training & Education Audit
• % of Managers/Supervisors
completing safety leadership
training
• Number of H&S meetings
conducted
• % of employee attendance at
H&S meetings
• % employees completing
required compliance training
• % persons leading a safety
meeting
• % of employees completing
required training

20. 4 Elements to Audit
• Management Leadership and Employee Involvement
• Worksite Analysis
• Hazard Prevention and Control
• Safety and Health Training
Effective Safety and Health Management System

21. One VPP Company
• Job Hazard Analysis is completed
as part of every job
• Pre-Job Briefs are required for all
work performed at the station.
• All briefs are required to include
job hazards, special precautions,
and appropriate personal
protective equipment.
• Industrial hygiene surveys for
asbestos, lead, noise, and
radiation have been conducted
and programs have been
developed as Control Programs.

22. Job Hazard Analysis
• National Tire Shop
• What potential hazard
would be caught with a
JHA?

23. 4 Elements to Audit
• Management Leadership and Employee Involvement
• Worksite Analysis
• Hazard Prevention and Control
• Safety and Health Training
Effective Safety and Health Management System

24. Dow 30 Heat Map
• Audit is focusing on High Risk/High Severity items.

25. Track Like VPP
• 2/21/2011 - Teammates thought top hand
rails in the melt shop needed to be free of
signage. Signs were removed and relocated to
bottom rails on 3/1/2011.
• 2/1/2010 - Teammates reported concerns
with man baskets that are sold as attachments
to forklifts and it was decided to do away with
all on the property on 3/3/2010.

26. Construction Pre-Qualification
– Years Experience in Work
Process
– Experience Modification
Rate (EMR)
– OSHA Total Recordable
Incident Rate and Lost
Work day Case Rate
Information
– Safety Programs
– Training Documentation

27. 2009 Empress Casino Fire
• $340 million in damage
• Lawsuit blames the fire
on general contractor and
five other companies
• The suit claims a welder
inadvertently sparked the
blaze in the kitchen area,
which ignited greasy
cooking residue and
spread flames throughout
the attic and truss space.

28. Questions?
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