Safety Inspection Process for a Manufacturing Facility

Energy Control — LOTO Programme Inspection

The LOTO programme audit checks both the programme-level requirements (written procedures, training records, hardware availability) and the task-level implementation (are technicians actually following LOTO before starting maintenance work?).

• Confirm written LOTO programme exists — facility-wide energy control programme document reviewed and current
• Confirm machine-specific LOTO procedures are written and posted — for every piece of equipment requiring LOTO; posted at or accessible at the equipment
• Verify LOTO hardware is available — sufficient locks per technician, hasps, tags, lockout boxes, and valve lockouts; damaged hardware replaced
• Confirm all LOTO-authorised personnel are trained — training records current; any new personnel trained before performing LOTO
• Conduct an observed LOTO inspection — observe a LOTO procedure being performed; confirm the technician follows the written procedure correctly; required annually per OSHA 1910.147(c)(6) by an authorised employee who is not the one performing the LOTO
• Document the LOTO programme annual inspection — in writing; required by OSHA; include machine, employee, date, and inspector

Machine Guarding Inspection

• Inspect every machine with moving parts — confirm all required guards are in place and functioning; no guards removed or bypassed
• Verify guards are not removable without a tool — guards that can be casually removed by hand do not meet OSHA requirements
• Inspect in-running nip points — all points where two rotating surfaces create an in-running nip (rollers, gears, belts/pulleys) guarded
• Inspect belt and chain drives — all exposed belts, chains, and pulleys guarded; guards intact
• Confirm interlocks are functional — guards with interlocks tested; machine stops when guard is opened
• Inspect abrasive wheels and grinders — wheel guards in place; tool rests adjusted correctly; tongue guards within specification
• Document any missing or damaged guards — as corrective actions with immediate timeline for correction; no production use until guarding is restored

PPE Inspection

• Confirm PPE hazard assessment is current — written assessment identifying PPE requirements by area and task; reviewed annually and when tasks or hazards change
• Confirm PPE is provided at no cost — required PPE available and accessible to all workers who need it
• Inspect PPE condition — hard hats, safety glasses, hearing protection, respirators, gloves, and safety footwear inspected; damaged or expired PPE replaced
• Confirm PPE training is current — workers trained on when PPE is required, how to use and maintain it; training records on file
• Verify PPE is being worn correctly — observe workers in areas requiring PPE; any non-compliance addressed immediately

Emergency Systems, Exits & First Aid

• Inspect all emergency exits — unobstructed, marked, and illuminated; all exit doors accessible; no storage blocking aisles leading to exits
• Test emergency lighting — confirm emergency lighting activates on power failure; batteries functional
• Inspect fire extinguishers — in designated locations; current inspection tag; unobstructed access; pins and seals intact
• Inspect fire suppression systems — sprinkler heads unobstructed (18-inch clearance); no material stored near sprinkler heads; last tested within required interval
• Confirm eyewash and emergency shower stations — in areas with chemical hazards; unobstructed; tested weekly; flow adequate
• Inspect first aid stations — stocked, accessible, and known to workers; trained first aiders identified per OSHA/applicable requirements

Hazardous Materials & Chemical Safety (HazCom)

• Confirm SDS are available — for every hazardous chemical used, stored, or produced; in a known, accessible location for all workers
• Confirm all chemicals are labelled — per GHS (Globally Harmonized System); secondary containers labelled; no unlabelled chemicals
• Inspect chemical storage areas — incompatible chemicals segregated; flammables in flammable storage cabinets; quantity limits not exceeded; secondary containment for liquids
• Confirm HazCom training is current — all workers handling hazardous chemicals trained; training records on file
• Inspect for chemical leaks or spills — any uncontrolled releases noted and immediately reported; spill response equipment available and accessible

Housekeeping, Ergonomics & General Facility Safety

• Inspect all walkways and aisles — clearly marked, unobstructed; no material stored in aisle ways; adequate width maintained
• Inspect floors for slip and trip hazards — oil, water, or material spills; uneven surfaces; cables or hoses crossing walkways
• Inspect lighting levels — adequate illumination in all work areas and storage areas; failed bulbs replaced
• Inspect racking and storage — maximum load capacities posted and not exceeded; items stored safely; no overhead storage that creates a falling object hazard
• Inspect powered industrial trucks — pre-shift inspection records current; pedestrian separation measures in place; speed limits posted

Incident Reporting & Safety Programme Governance

• Confirm OSHA 300 log is current — all recordable incidents logged; 300A summary posted from February 1 to April 30
• Review near-miss reporting — is the near-miss reporting culture active? Near misses reported and investigated; not just major incidents
• Confirm safety training records — current for all required training (LOTO, HazCom, forklift, emergency response, PPE); new employees trained before exposure
• Review open corrective actions from previous inspections — all findings from the last safety inspection have been closed or are on track
• Confirm safety committee is meeting — safety committee or equivalent regular meetings; minutes retained
• Document the inspection findings — all observations, findings, and corrective actions formally recorded; issued to responsible managers with deadlines