Comprehensive Safety Evaluation Facility: Period: Mid-Year Year: 2012 Evaluator: Jamie Williams SAFETY CULTURE DEVELOPMENT Items Noted Point Factor Total Points 1 Safety Commitment 0 1.0 Max = 10 0.0 2 Actions Items from Previous Year s Evaluation 0 1.0 Max = 10 0.0 3 Safety Communication 4 Safety and Health Training 5 Recordkeeping 6 Safety Task Assessments (STA) 7 Safety Committees 8 Near Misses Safety Culture Points Accounts for 60% of the Overall Evaluation Grade Base Points (Max = 100): Bonus Points (Max = 50): Total Points (Max = 150): 0.0 Comments EVALUATION 1
SAFETY PROGRAM MANAGEMENT Comprehensive Safety Evaluation Facility: Period: Mid-Year Year: 2012 Evaluator: Jamie Williams Items Noted Point Factor Total Points 1 General Safety 2 Fire Prevention and Control 3 Electricity 4 Compressed Gas Usage and Storage 5 Machine and Equipment Guarding 6 Mobile Equipment 7 Personal Protective Equipment (PPE) 8 Fall Protection and Prevention 9 Housekeeping 10 Hazard Communication Safety Program Points Accounts for 40% of the Overall Evaluation Grade Base Points (Max = 100): Bonus Points (Max = 50): Total Points (Max = 150): 0.0 Comments EVALUATION 2
Comprehensive Safety Evaluation Facility: Period: Mid-Year Year: 2012 Evaluator: Jamie Williams Total Base Points (Max 200): Total Bonus Points (Max 100 ): Total Points (Max 300): Base Safety Evaluation Score: 10% Bonus Safety Evaluation Score: Overall Evaluation Grade: 200 0 200 100% 0% 100% Reviewed By: Facility Manager: Operations Manager: Safety Culture Base and Bonus Grade Safety Program Base and Bonus Grade 100% * 0.0 Points (Continuous Improvement) A B C 100% * 0.0 Points (Continuous Improvement) A B C D D Overall Evaluation Total Base and Bonus Evaluation Grade: 100% * 0.0 Points (Continuous Improvement) A B C D Grade Scale 90-100 80-89 70-79 69 and Below Outstanding Excellent Average Needs Improvement A B C D EVALUATION 3
Safety Commitment Blank cards are available. Employees have current, signed cards accessible and understand the its purpose Supervisors review cards individually in groups of three (3) employees Management addresses genuine employees Safety related concerns. Employees are fully knowledgeable of Safety procedures and requirements. Management can navigate Insight safety page and obtain required documents. Examples: Incident/Near Miss Reporting Procedure and Forms; Safety Alerts; Wellness Calendars. Management is familiar with incident investigation and reporting procedures presentation on Insight. Employees (100%) attend safety meetings. Employees participate in safety inspections. Employees participate in safety committees. Employees report near misses. Employees submit safety suggestions. Contractors onsite are pre-qualified. Management develops action plans based on previous year s evaluation results. Plant has implemented Safety teams. Management develops action plans from Behavior-Based Safety (BBS) results and shares both during safety meetings. Employees help develop safety and health programs. Safety meetings are held more often than required. Facility has site-based safety recognition program. More than 50% of plant personnel participated in plant safety inspections with documented findings. Actions Items from Previous Year s Evaluation Management and Safety Committee have reviewed and understand previous end of year evaluation results with particular attention paid to their location. Minimum of top three noted deficiencies from previous year evaluation should ve been addressed. Safety Committee has addressed previous years audit and developed an action plan addressing the noted deficiencies and submitted to the next level of management for review. Documented and verifiable information of physical improvements and training performed is available. More than the top three noted deficiencies have been addressed with a formal action plan and documented results. New implemented processes addressing noted deficiencies are clearly visible. Safety Task Assessments (STA) Blank and current forms are available. STAs are performed daily. Non-Routine STAs are performed as necessary. Post-job meetings are held for Non-Routine STAs. STAs adequately cover the facility and/or job's hazards. STAs include wellness messages. Employees print names clearly on STAs. Employees lead STAs. Safety Communication "Why I Work Safe, Why I Live Healthy" board is visible and has relevant postings. Adequate safety posters, banners, and messages found throughout the facility. Safety inspections are reviewed during safety meetings. Previous Safety committee minutes and actions items are reviewed during safety meetings. Near misses are reviewed during safety meetings to create awareness. Safety suggestions are reviewed during safety meetings. Hazard assessment system is reviewed during safety meetings. Safety alerts reviewed during safety meetings and posted in plant bulletin board. Wellness activities are discussed during safety meetings. CULTURE CRITERIA Page 4 of 7 1 Evaluators ( 2 Locations ) are not limited to this criteria.
Safety and Health Training Employees receive required training on on-going basis. >New Hire Orientation; >MSHA Part 46 New Miner Training; > 4-day RM Driver Training (within 3 to 4 weeks of employment); > 2-day RM Driver Refresher (within 2 years of 4-day course); >LOTO Training / Refresher Employees receive training on site-specific issues monthly or as needed. Management receives reasonable suspicion training (learn to recognize drivers under the influence of alcohol and/or drugs). Plant management promotes participation of indirect employees (contractors) in monthly safety meetings. Management receives training on safety management. Examples: OSHA 10- or 30-Hour Training; Regulatory Training. Management holds regulatory training sessions regularly to increase awareness and streamline practices. Management holds contractor-training sessions beyond regulatory requirements. Recordkeeping Required documents are posted, visible, and current. Examples: OSHA 3165; OSHA 300A (when applicable); MSHA 7000-3 (when applicable); General Safety Rules; Incident/Near Miss Reporting Procedure; STA Procedure; STA Supervisor's Pledge; Emergency Action Plan; Hazard Assessment System; Safety Alert; Safety Committee Minutes. Required information is recorded and reported to Safety Department complete and on time. Examples: Incidents; Near Misses; Safety Meetings, Training, Committee Minutes, and Suggestions. Document preservation and destruction conforms to Safety Records Retention Policy. Example: Incidents; Near Misses; Safety Meetings, Training, Committee Minutes, and Suggestions. Contractor safety data is recorded and reported to the Safety Department. Incidents involving contractors are investigated and reported to Safety Dept. Safety Committees Safety committee conducts regularly scheduled monthly meetings. Near misses and incidents are reviewed and analyzed during safety committee meetings. Safety suggestions are rejected or approved during safety committee meetings. Hazard assessment system form is reviewed and updated during safety committee meetings. Meeting minutes are shared and recorded in the Titan Safety Committee Minutes Form and include action items and safety suggestions. Updated form available on Insight. Safety committee conducts facility safety inspections. Hazards noted during facility safety inspections are recorded on Hazard Assessment System form. Safety committees should be composed of management and frontline employees. Employees facilitate safety committee meetings. Corrected hazards noted during facility safety inspections immediately. Incorporate lessons learned gathered from incidents investigations and audits into training as appropriate. Plant has documented Guest Speakers on safety topics. Near Misses Current near miss forms are available for employee access. Completed near miss reports were reviewed and discussed during monthly meetings. Corrective action is taken by local management on reported serious near misses. Minimum of one near miss per month reported to Safety. CULTURE CRITERIA Page 5 of 7 1 Evaluators ( 2 Locations ) are not limited to this criteria.
General Safety Facility has emergency action plan with recorded training and drills. Workplace exams are performed daily (MSHA). Facility is in good condition (physical/structural: beams, catwalks, walkways, etc). Facility has adequate signage to identify hazards. Work areas are properly illuminated. Confined spaces are marked clearly. Confined spaces that require reclassification are properly classified. Tools are used in proper and safe manner. Tools are not used beyond design capacity intended by manufacturer. First aid kits are stocked and up-to-date. Eyewash stations are in good condition. Railway areas are in good condition. Haul roads are clearly marked and directionally identified. Fire Prevention and Control Emergency exits function properly, have proper signage and illumination, and are free of obstruction. Fire extinguisher locations are identified and accessible. Fire extinguishers are located at distances that meet regulatory requirements. Fire extinguishers are charged and have an intact seal on discharge handle. Fire extinguishers are inspected monthly and inspection records are available. Fire extinguishers have up-to-date annual tags. Smoke and fire detectors function properly. Signs are posted at flammable materials areas ("No Smoking Or Open Flames Within 50 Feet", etc). Structural items near roadways and driveways are painted for increased visibility. Egress routes and emergency exits have heightened identification. Facility has health station for employees and visitors. Facility has map of fire extinguisher locations posted in designated areas. Facility has map of evacuation rendezvous points (primary and backup) posted in designated areas. Electricity Electrical wiring is enclosed in conduit and free of damage. Extension cords are free of damage and are not wired permanently (no splices or cuts in insulation). Electrical panels, circuit breakers, and emergency shut-offs are accessible. Breaker and disconnect boxes have required labeling. Individual circuits are marked as to what they control. Junction boxes have covers and energized parts are enclosed. GFCI are used where needed. Energy control (LOTO) procedures binder is accessible. Locks and tags are provided and energy control (LOTO) procedures are followed. Electrical tools and equipment are properly grounded. Required ground testing is done annually and is properly color-coded (MSHA). Facility meets NFPA Part 70E. Breaker and disconnect boxes are labeled consistently. Disconnects, cut-offs, and emergency stops are accessible, labeled clearly for what they control, and brightly marked for easy identification during emergencies (more than regular labels and factory paint). Interior breaker labeling is displayed on breaker box exterior (interior must remain labeled for each breaker). Locks and tags have owner's picture, name, and contact information when used. Compressed Gas Usage and Storage Bottles are upright, marked, capped, and stored properly (gas/oxygen separate, etc). Bottles are secured properly while transported and used. Torch cylinder valves are closed and lines are drained when unattended. Torch lines have flashback suppressor on regulator and torch head. Compressed gas lines and hoses are in good condition. Proper igniting tools are provided (strikers). Storage areas are labeled and/or marked clearly (gas type, full, empty). Bottles have secure bracing (not chains or straps). Torch tip cleaning equipment is provided and employees receive training on proper equipment use. Machine and Equipment Guarding Belt head and tail pulleys have permanent guards. Guards are painted for high visibility. Motor components and shafts with exposed hazards are guarded properly. Guards are labeled to identify pinch points/hazards. Pulleys and rollers within 7 feet of ground and working levels are guarded properly. Abrasive wheel guards are in place, extra eyewear is available at Emergency stop cords are in place and function properly. storage areas, signs are posted at storage areas, and employees Perimeter guards are in place and e-stops on gates function properly. receive training on hazards. Utility equipment near travel and work areas are guarded properly. Fan blades are guarded properly. Bench grinders and abrasive tools are guarded properly and mounted (tool rest set 1/8 inch or less from disc and eye shields). PROGRAM CRITERIA Page 6 of 7 1 Evaluators ( 2 Locations ) are not limited to this criteria.
Mobile Equipment Mobile equipment is not used beyond design capacity intended by manufacturer. Mobile equipment is parked properly when not used. Seat belts function properly. Mobile equipment have fire extinguisher. Pre-trip inspections are performed and recorded. Post-trip inspections are performed (DOT). Mobile equipment with critical safety defects is taken out of service. Personal Protective Equipment (PPE) Adequate PPE is provided for employees and visitors. Employees receive training on proper PPE use. PPE is in good condition (free of defects, etc). PPE is not expired. PPE is stored properly. PPE is worn properly. Employees use PPE (seat belts, safety glasses, hard hats, etc). Fall Protection and Prevention Fall protection assessments addressing anchor points and equipment are performed. Harnesses and lanyards are provided and inspected monthly. Employees receive training on proper harness and lanyard use. Employees demonstrate knowledge of proper harness and lanyard inspection procedure. Platforms, catwalks, and stairways have standard railing system (handrail, midrail, toe board). Stairway and ladder way floor openings are guarded, except entry and exit (chain or spring gates). Ladders and cages are in good condition. Fixed ladders have cages attached (ladders 7 feet above ground and working levels). Personnel lift cages have proper ratings and meet regulatory standards. Slump, wash, and safety (Carbis) racks are in good condition, free of debris, and have adequate lighting. Haul roads are properly bermed. Mobile equipment with propane tank have secondary chain that prevents losing the tank should the band clamps fail. Facility has written PPE inspection program that covers PPE defect identification, PPE replacement, and training. Extra PPE is kept on inventory beyond what employees and visitors use. Employees are assigned an individual harness and lanyard. Harnesses and lanyards have separate storage cabinet, labeling, inspection tags, and posted inspection steps, that demonstrate the facility does more than just provide them. Ladders are inspected daily and inspection records are available, even when not used. Handrails and midrails have consistent, fresh paint throughout the facility. Hazard signage is present in confusing and low light areas. Housekeeping Catwalks, walkways, and passageways are free from obstruction, slip, trip, and fall hazards (accumulated material spills, uncoiled hoses, debris, etc). Electrical rooms are clean and free of standing and/or leaking water. Mechanical rooms are free of slip hazards. Break areas are clean and orderly. Bathrooms are clean and supplied (toilet paper, soap, hand towels). Company vehicle cabs are clean (utility trucks, loaders, haul trucks, F150s, take-home vehicles). Materials are stored/stacked properly (pallets, drums, totes, equipment, tools, etc). Trash is disposed of properly and there are sufficient waste receptacles. Spill kits are provided and identified clearly. Truck parking areas have means of preventing ground contamination due to spills. All trash bins have covers and are closed (OSHA). Facility has recycling program and receptacles are labeled clearly. Hazard Communication (HazCom) Material safety data sheets (MSDS) and chemical inventory lists (CIL) are updated annually. MSDSs and CILs are readily available. An MSDS is available for each chemical on site. Hazardous materials are stored properly. Flammable aerosols are stored in flammable cabinets. Signs are posted at hazardous materials areas. Drums and containers are labeled and/or marked properly. Chemical inventory kept on E-File and updated monthly (minimum). Storage areas are VERY clean and organized (no oil rags, etc). Flammable cabinets are VERY clean and organized (items stored by group). HazCom signs are VERY clean and readable. Employees demonstrate awareness of HazCom training (MSDS and Labeling). PROGRAM CRITERIA Page 7 of 7 1 Evaluators ( 2 Locations ) are not limited to this criteria.