INTRODUCTION
Company XXXX is a global manufacturer of
polymeric medical grade components and systems for injectable drug delivery,
including stoppers, seals for vials, and closures.In view of Company XXXX
varying customer’s products dimensional and functional requirements, it’s
facility stored and employed significant amount of hazardous and flammables
chemicals for it’s manufacturing operations.
Similarly to power and fuel up it’s utility
and manufacturing operations, Company XXXX house statutory equipment such as
the steam boilers, pressure vessel , air
compressor and cooling tower in its site located at XXXX.
Following two fatal accidents and numerous
safety lapses reported in its manufacturing site prompted Company XXXX Director
to formally invite the HSE Consultancy and Services Pte Ltd to conduct an audit
on it’s Safety and Health Management System to identify the strengths and
weaknesses of its Safety and Health Management System
OBJECTIVE
The purpose of the Safety Management System
audit is to assess Company XXXX Safety Management System Manual based on the WSH Act and its subsidiary legislation as
well as the Singapore Standard SS
506 Part 3 : 2006 Occupational safety and health (OSH) management system –
Requirements for the chemical ,by gathering evidence on System
Implementation through Sampling, Document Review, Interview of Personnel and
Physical Inspection.
SCOPE
The scope of this audit was limited to
assessing 7 Elements out of the 14 Elements of Company XXXX Safety and Health
Management System
The Safety and Health Management System
Elements Assessed are tabulated below
Element
# |
Element
Description |
Element
1 |
Safety
Policy |
Element
2 |
Safe
Work Procedure |
Element
3 |
Safety
Training |
Element
4 |
Group
Meetings |
Element
5 |
Incident
Investigation and Analysis |
Element
9 |
Safety
Inspections |
Element
11 |
Hazard
Analysis |
The Safety and Health Management System audit
is undertaken in Company XXXX located at XXXX
The Auditee site comprised of the following
utilities and facilities which will be inspected
on site during the scheduled audit from period 20 July 2013 to 21 July 2013
Utilities / Facilities
located in Company XXXX |
Steam Boiler |
Air Compressor room |
Autoclave |
Toxic Industrial Waste
Storage |
Chemicals Storage |
Flammable Chemical Storage |
Steam Boiler |
Air Compressor room |
Cooling Tower |
Dust Collector |
AUDIT
CRITERIA
The audit criteria strictly adhere to the Ministry of Manpower Guidelines on the
Audits of Safety and Health Management System where the audit on the SHMS
is conducted in accordance with the relevant WSH legislation and guidelines set out for each industry.
The audit on the SHMS is based on the WSH Act
and its subsidiary legislation as well as the Singapore Standard SS 506 Part 3 : 2006 Occupational safety and health
(OSH) management system – Requirements for the chemical industry
AUDIT
PROTOCOL
The following on-site SHMS audit protocols
are to be observed by the auditors. And the activities involve in each phase is
tabulated under audit methodology
·
Pre-audit Activities
·
On-Site Audit Activities
·
Post Audit Activities
AUDIT
METHODOLOGY/PROCESS
The conduct of the Safety and Health
Management System in Company XXXX involve various phases, which include the
pre-audit phase, audit phase and post audit phase activities
Tabulated below is the list
of activities undertaken during the various audit phases
Audit Phase |
Activities |
Responsibility |
Timeline |
Pre-Audit Phase |
Gathering of background information
from audited organization using pre-audit questionnaires and obtain previous
year audit report |
Lead auditor email organization Audited organization furnish the organization
background information as per established questionnaire |
2 weeks |
Developed audit plan and audit
schedule upon received required information from the organization |
Lead auditor |
1 weeks |
|
Pre-Audit meeting with Auditee |
Pre-site visit by lead auditor to
confirm the audit plan which include audit schedule ,audit sampling, audit
methodology ,audit criteria |
Lead auditor |
1 weeks |
Notification of confirmation of
audit date, audit agenda, audit plan, and audit schedule |
Lead auditor |
1 month |
|
Audit Phase |
Opening address -explain to auditee the audit
objective, audit purpose, scope and audit methodology and identify personnel
for interview |
Lead auditor |
- |
Familiarization tour by site audit
coordinator to provide an overall view
of the site facility to the audit team |
Site audit coordinator |
- |
Audit Phase |
Activities |
Responsibility |
Timeline |
Audit Phase |
Documentation
Review -assess site safety and health
management system manual , -Safety Policy -Statutory equipment inspection
schedule -WSH training records of workers,
supervisors and managers -safe work procedures for high risk
activities -safety committee inspection records -safety committee team meeting
minutes -risk assessment of risk activities Use of checklist to confirm findings
from the assessment of the company SHMS during documentation review phase |
Team Auditor |
- |
Interview
of Person Interview of person which include contractors,
workers, supervisors, engineers and managers for verification of information Use of checklist to confirm findings
from the assessment of the company SHMS during the interview of personnel
phase |
Lead Auditor |
- |
|
Audit Phase |
Site Physical
Inspection Observe processes and procedures
related to health and safety which include housekeeping, production
processes, job task, machine, equipment function and the use of PPE etc to
confirm findings gathered from the document review and interview of personnel To ascertain actual physical system
compliance in the factory Obtain general impression of the
state of the safety and health of the factory Use of checklist to confirm findings
from the assessment of the company SHMS during site physical inspection phase |
Team Auditor |
- |
Audit
Phase |
Closing
meeting Closing address with site management
presenting the audit findings, observations
and conclusion and allow clarification from site management Timeline on receiving of official
audit report Timeline on the follow up of the
identified action items |
Lead Auditor |
- |
Post-Audit Activities |
Preparation of draft SHMS Audit report
for Company XXXX management team and give them 2 week grace period to review
and comment Issue the final SHMS Audit report 1 month from the date of actual
audit Develop Action Plan on identified
audit findings by ·
Proposed Action ·
Resolve differences ·
Establish Responsibility ·
Determine schedule for next follow up Follow up to monitor progress of
audit action progress, verification of audit action items and verification of
effectiveness of action items |
|
|
INTERVIEW
PERSONNEL
During the interview of personnel, Company
XXXX employees from different levels of the
organizational hierarchy which include company management, line management,
workers,
OSH personnel and even subcontractors and suppliers are randomly selected and sampled.
The names of the
interviewees were withheld and not disclosed nor published in this audit
report for confidentiality reasons
Interview checklist developed for the
purpose of assessing the SHMS Elements and designed for different levels of
staffs within Company XXXX organizational hierarchy are used to assess
Company XXXX SHSMS effectiveness
Company XXXX Audit Coordinator is responsible for over-seeing
the coordination and the scheduling
of Company XXXX employees for interview with the
auditors.
AUDIT
CLASSIFICATION
Audit Finding Classification
At the
completion of the audit, the lead auditor will discuss with the team auditor to
make an assessment about the findings taking into consideration both positive
and negative aspects and classify the audit findings based on the following
criteria
Major
An
audit finding is Major if any of the following criteria apply, presenting a
significant risk:
-an EHS Management System element is largely missing or its
implementation is almost completely ineffective
-the site doesn’t comply with a legal obligation
-repeat findings have arisen for the same issue in consecutive
audits
-a significant risk (to EHS) is present.
Minor
An
audit finding is Minor if any of the following criteria apply, presenting a
non-significant risk:
-an effective but incomplete system element requires some
improvements
-non-significant risk (to EHS) is present.
SUGGESTION
-A
Suggestion will be made if the auditor is aware of situations which may benefit
the site. This need not be limited to the scope of the audit.
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