Assignment on

Safety Audit Report on Walton Hi-Tech Industries Ltd.

Submission Date : 12 August, 2014
Submitted to :
Dr. Md. Mamunur Rashid,
Management Counselor, BIM
Prepared by : Mahmudul Haque,
Participant
ID:14DH221
Batch : Evening
3(2014), PGDHRM,
BIM


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Date: August 12, 2014
To
Dr. Md. Mamunur Rashid
Management Counselor
Bangladesh Institute of Management (BIM)
Dhaka.

Subject: Assignment on Safety Audit report on Walton Hi-tech Industries Ltd.
Dear Sir
With due respect this is my pleasure to submit my assignment on Safety Audit
report on Walton Hi-tech Industries Ltd. Walton Hi-tech Industries Ltd maintains
standards ISO 14001: 2004 & BS OHSAS 18001: 2007 for Environmental,
Occupational health & Safety Management System. Walton Hi-tech Industries Ltd
is very much conscious about Environmental, Occupational health & Safety
Management System so Walton Hi-Tech Industries Ltd has the individual
department named ISO department to monitor and measure this standard. During
completing this assignment I acquired a lot of knowledge on Industrial Safety,
Health and Welfare which will be very helpful in my professional career in the
near future.

This audit report is fully practical oriented and I hope this audit report will fulfill
your requirement and expectations. I would be highly glad if you guide me for any
additional requirement that I could not brought in my report.

Sincerely yours

Mahmudul Haque
Student ID: 14DH221
Batch: Evening - 03(2014), PGDHRM, BIM

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Acknowledgement
This is the first time I participated Environmental, Occupational health & Safety
Management System audit to prepare this assignment. To be honest it was one of
the memorable moments in my career. Earlier we discussed a lot in monthly
General meeting but this moment I learnt practically about safety management
systems requirement and how are they being implemented in Walton Hi-tech
Industries Ltd. I would like to thank Dr. Md. Mamunur Rashid to choose Safety
Audit report on Walton Hi-tech Industries Ltd. as assignments topic. His lecture
and guide lines helped me a lot to complete the audit and to prepare the audit
report. I would also like Mr. Abdur Razzak, Management Representative (MR) of
Environmental, Occupational health & Safety Management System for his
tremendous support to from beginning to end of this audit program.
I am glad to be a part of Audit Team on the Environmental, Occupational health &
Safety Management System.











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Company Profile:

The brand WALTON is owned and operated by R.B. GROUP head quartered in
Dhaka, Bangladesh. Its principal activities are designing, manufacturing,
exporting, retailing of consumer electronics, home appliances, mobile phones and
automobiles. The manufacturing and product design operations are carried out at
Walton Hi-Tech Industries Limited (WHIL).

R.B. GROUP has several subsidiary companies under it for distributing WALTON
products spread across Bangladesh and International Market.

Established in 2006, WHIL has achieved a considerable market share within the
industry. It is the pioneer in manufacturing most comprehensive range of products
including Multi-Staged Refrigerator, Freezer, Air Conditioner, Automobile and
Home Appliance. WALTON products are recognized for their quality, ease of use
and innovative technology.

WALTON uses best-in-class technologically advanced manufacturing facilities to
validate and ensures all products innovations are designed around peoples need
and aspirations touching ones life every day.

WALTON has countrywide Retail Sales Outlets and more than 100 Service Points
with highly skilled and efficient technical personnel. It has International
Standardization Certification ISO 9001:2008 for Quality Management System and
ISO 14001: 2004 & BS OHSAS 18001: 2007 for Environmental, Occupational
health & Safety Management System.








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Audit Plan

Date of Audit 20/07/2014
Type of Audit Internal Audit
Method Sample Based
Opening Meeting 10:00 am -10:30 am
Document Check 10:30 am -11:00 am
Site Visit 11:00 am-01:00 pm
Launch Break 01: 00 pm -01:40 pm
Auditors Discussion 01:40 pm:02:00 pm
Site Visit 02:00 pm-05:00 pm
Closing Meeting 05:00 pm-05:30 pm
Auditor Lead Auditor: Mr. Abdur Razzak
Members:
Mahmudul Haque
Ashik Al Mamun
Mojahidul Islam
Kh. Shahriar Murshid
Ahasan Tarique
Foysal Wahid
Moklesur Rahman
Shafiquzzaman Tayeb
A.K.M Ehsanul Hossain
Alak Chakraborty
Enamul Haque








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Opening Meeting the opening meeting is the formal initiation of the audit.

Opening Meeting Agenda
1. Welcome
2. Sign In sheet
3. Introductions
4. Review of Audit Objective/Scope as stated on the Internal Audit Notification
5. Questions regarding Objective/Scope
6. Are there any additional concerns/changes that need to be addressed?
7. Discuss Audit timetable
8. Discuss Audit Methodology
9. Questions regarding Audit Methodology
10. Documents Review
11. Confirmation of formal communication channels between the Audit Team and
the Auditee.
12. Are there any confidentiality issues the Audit Team needs to be aware of?
13. Briefly discuss the closing meeting: Interview Reports, Concerns and Internal
Audit
14. Schedule Closing Meeting
15. Final questions/comments
16. Closing









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Closing Meeting: The primary purpose of an audit closing meeting is to present the audit
findings and conclusions, ensure a clear understanding of the results, and agree on the timeframe
for corrective actions.

Closing Meeting Agenda
1. Acknowledge and thank those who participated
2. Sign in Sheet
3. Reminder of objective/scope of the audit
4. Share positive findings
5. Explain opportunities for improvement/observations
6. Explain methods that will be used for identifying and recording nonconformities
7. Identify limitations of the audit
8. Present audit findings and summary statement* (explain final report will be
delivered with 2 to 3 business days)
9. Agree to necessary corrective action
10. Agree to timing for completion of corrective action (answer is requested within
ten days; however the actual fix may take longer)
11. Ask auditees if further clarification is needed
12. Conclude the meeting

*Summary Statements
1) Total number of nonconformities
2) Where the nonconformities were found
3) Areas/functions where no nonconformities were found
4) Observations of areas of concern
5) Management system requirements most often not met
6) Recommendations, if appropriate






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Audit Objective: The objectives of internal safety audit program include:
1. Verify safety programs have been developed/implemented in accordance
with system safety program plan requirements
2. Assess effectiveness of the industrys system safety programs
3. Identify program deficiencies
4. Identify potential hazards in the operational system and weaknesses in the
system safety programs
5. Verify prior corrective actions are being tracked for closure
6. Recommend improvements to the system safety program
7. Provide management with assessment of status and adequacy of system
safety program
8. Assure continuing evaluation of safety-related programs, issues, awareness
and reporting

Audit Method:

The methodology used in this audit consisted of the following -
Trained Internal auditors have undertaken an OHSMS audit using relevant WHIL
OHSMS Audit documentation. This documentation includes:
Three types of audit activities have used to assess the level of conformance of the
area name to the WHILs OHSMS policy:
1. Conducting interviewing with relevant staff e.g. Head of department, Unit
Managers and general staff.

2. Review of documentation and records e.g. workplace inspections, OHS
Hazard and Risk Register, Corrective Action table, Safety Policy, position
descriptions, OHS Training Plan, and OHS Induction Checklist.

3. Observation during site inspections e.g. Workshops, storerooms.


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Audit Scope:
The scope of the audit is to cover:
Risk assessment
the assessment of risks posed by non-compliance
with the license standards and development of a
risk-based audit plan to focus on the higher risk
areas, with less intensive coverage of medium and
low risk areas;

Process
compliance
the effectiveness of systems and procedures in
place throughout the audit period, including the
adequacy of internal controls;

Outcome
compliance
the actual performance against standards
prescribed in the license throughout the audit
period;

Output compliance
the existence of the output from systems and
procedures throughout the audit period (that is,
proper records exist to provide assurance that
procedures are being consistently followed and
controls are being maintained);

Integrity of
performance
reporting
the completeness and accuracy of the performance
reporting to the Authority;









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Audit Tool Definitions

C Conformance
A judgment made by the auditor that the activities
undertaken and the results achieved fulfill the specified
requirements of the audit criteria.
PC
Partial
Conformance.
A judgment made by the auditor that the activities
undertaken and the results achieved partially fulfill the
specified requirements of the audit criteria. While further
improvements may still be possible, the minimum
requirements are being met.
NC
Non-
Conformance
A judgment made by the auditor that the activities
undertaken and the results achieved do not fulfill the
specified requirements of the audit criterion. This may be
caused by (a) the absence or inadequate implementation of a
system or part of a system; or (b) failures by Supervisors
and/or workers to follow documented systems or
procedures, or (c) lack of evidence to demonstrate that
requirements are being met.
NA
Not
Applicable.
A judgment made by the auditor that this criteria does not
apply to the work unit
NV Not Verifiable
A judgment made by the auditor that these criteria cannot be
verified.


Audit Criteria

No.
SAFETY ITEM
Acceptance
Comment &
Corrective Action
Housekeeping
1. Storage spaces are orderly with ample aisle
space.
C
2. Floors are clean and free of wires, tools, etc. C
3. Stairways are clear of clutter and spills. C
4. Temperature is within established guidelines. C

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No.
SAFETY ITEM
Acceptance
Comment &
Corrective Action
5. Walls, windows, and ceilings are well
constructed and free of hazards.
C
6. Machines, benches, and other equipment are
arranged so as to conform to good safety
practices.
C
7.
Illumination is safe, sufficient, and well
placed.
PC
One energy savings
bulb was disabled in
AC R&D Department
two days ago, no
action taken yet.
Action was taken
immediately.
8. Ventilation is adequate. C
9. Lockers are inspected regularly for
cleanliness and fire hazards.
C
10. Locker doors are kept closed.
PC
Lockers of Mr. Jalils
(AC Department was
not found Closed).
Promised to do it
regularly.
11. General appearance is orderly. C
12. Special tool racks are kept in orderly
condition and provided at benches and
machines.
C
13. Tools are stored properly. C
14. Tools, supply, and/or material rooms are
orderly.
C
15. Sufficient scrap boxes are provided. C
16. Scrap stock is put in scrap boxes promptly. C
17. Materials are stored in an orderly fashion and
in a safe condition.
C

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No.
SAFETY ITEM
Acceptance
Comment &
Corrective Action
18. Oily rags and waste are placed in a spring lid
metal container and the container is emptied
frequently.
NV
19. The lab is sanitized to meet health code
where appropriate.
NV
20. Oil spills and other slippery substances,
which might result in an injury-producing
fall, are promptly cleaned up.
C
21. Electrical wires, cables, pipes, or other
objects that cross aisles are clearly marked
and properly covered.
C
22. Covers or guardrails are provided to prevent
persons from falling into drainage ditches,
open pits, vats, tanks, etc.
C
23. Load ratings are posted on all upper storage
areas above seven (7) feet.
C
24. Multiple appliance plugs in the receptacle
outlets do not overload the circuits.
C
25. All electrical wiring is properly insulated. C
26. Ground fault devices protect exposed
receptacles and water coolers.
C
27. All switches in electrical boxes are identified
as to function.
C
28. Extension cords are not used as permanent
wiring.
C
29. All electrical equipment is installed in a neat
and workman-like manner.
C
30. All electrical equipment, such as fuse boxes,
switch boxes, etc., are firmly secured to the
surface on which it is mounted.
C
31. Ground fault devices (GFI) are provided
where required.
C
32. Ladders are maintained properly. C
33. Corners are clean and clear. C

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Medical Services and First Aid
34. Emergency facilities for drenching or
flushing the eyes are available within the
work area where the eyes may be exposed to
injurious, corrosive materials.
C
35. Emergency facilities for drenching the body
are available within the work area where the
body may be exposed to injurious corrosive
materials.
C
36. The first aid kit is adequately stocked,
including rubber gloves.
C
37. A qualified individual administers first aid. C
38. Fire blankets are in place in those areas
where the potential for fire and explosion
exist. Large room have two fire blankets.
C
39. A blood borne pathogen plan is in place. C
40. The industry has two or more individuals
qualified to administer first aid.
C



Fire and Fire Extinguishers
41. Fire extinguishers are of proper type,
adequately supplied, properly located, and
maintained.
C
42. Instructors and staffs know location of and
use of proper types of extinguishers for
NC Some employees
are found who do
not use of proper

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various fires. types of
extinguishers for
various fires.
43. Fire extinguishers are inspected monthly and
tested frequently.
C
44. A durable tag is securely attached to the
extinguisher to indicate the date of
recharging and is signed or stamped by the
recharger.
C
45. Fire extinguishers are located in areas where
combustible liquids are stored or used.
C
46. Persons with handicaps are provided for in
fire and emergency evacuation plans.
NV



Doors and Emergency Exits
47. The number and location of exits are
adequate.
C
48. Fire and other evacuation plans are posted in
conspicuous locations in all areas.
C
49. Fire exits are lit and clearly marked. C
50. Doors that might be mistaken for exits are
marked NOT AN EXIT or marked so as to
identify their purpose, such as Storage
Room.
C
51. Emergency exit doors are not blocked by
equipment or debris.
C

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52. Doors open and close properly. C
53. Exit ways are wide enough to permit ease of
passage.
C
54. Doors that are designed for emergency exit
are kept unlocked from the inside and
equipped with panic-type hardware.
C
55. Doors swing to accommodate exit traffic. C


Hazardous Materials
56. Combustible and flammable
liquids/materials are properly stored and
safeguarded.
C
57. Oxygen and other compressed gases are
stored away from combustible materials and
in an upright position
C
58. Oxygen cylinders are separated from fuel gas
cylinders and combustible materials.
C
59. Dangerous materials are stored in metal
cabinets.
C
60. Compressed gas cylinders are legibly marked
to identify their contents.
C
61. Used oil is stored in drums or tanks with
proper containment in a dry area.
NV
62. Used oil is picked up by a reputable
hauler/recycler.
NV
63. All used oil drums or tanks are labeled
Used Oil Storage.
NV
64. Used oil is kept free from solvents, anti-
freeze, brake fluid, or any other substance
which would be classified as a hazardous
waste.
NV

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Equipment
65. Machines are arranged so workers are
protected from hazards of other machines,
passing staffs , etc.
C
66. Dangerous areas are properly indicated. C
67. All equipment control switches are easily
available to the operator.
NC In Refrigerator-2
Production
department one
switch was not
working properly.
68. All machines are locked out when the
instructor is out of the room.
N/A
69. Brushes are used for cleaning equipment. NC In Motorcycle
chassis department
one found washing
motorcycle using
cloth instead of
brush
70. Non-skid areas are provided around
machines.
C
71. Machines are in safe working order. C
72. Machines are properly guarded to comply
with safety codes.
C
73. Adequate supervision is maintained where
staffs are using machines and dangerous
tools.
C
74. Tools are kept sharp, clean, and in safe
working order.
NC In most of the
department tools
were not found
clean.

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75. Cooking and eating utensils and equipment
are properly disinfected.
C
76. Instructions for operating and stopping
machines are posted on or near the machines.
C
77. All electrical appliances, which may be used
in damp or wet locations, are properly
grounded.
C
78. All fans are guarded. C
79. All points of operation where employees are
exposed to injury are properly guarded.
C
80. All electric portable power tools are properly
grounded.
NV




Personal Protection
81. Safety glasses/goggles/eye protection are
provided and required for all work when eye
hazards exist.
C
82. If individual goggles are not provided, hoods
and goggles are properly disinfected before
use.
NV
83. Shields are provided for electrical welding. C
84. Aprons or lab coats are worn in the lab. C
85. Staffs remove rings and other jewelry when
working in the lab.
C
86. The proper kind of wearing apparel is worn
for the job being done.
C
87. Leggings, safety shoes, etc., are worn in
special classes requiring such protection.
C
88. A respirator is used when spraying in the
finishing room.
NV
89. Protective footwear is worn when moving C

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heavy equipment or materials.
90. Personal protective equipment is provided in
areas where noise levels exceed established
permissive exposure.
C
91. Persons who require prescription eyeglasses
wear safety lenses.
C


Instruction
92. Safety rules are posted. C
93. Printed safety rules are given to each staffs. NC None could show
the documents
94. Staffs sign the safety agreement. C
95. There is a safety committee. C
96. Safety contests are promoted. C
97 Videos are used in safety instruction. C
98 Safety posters are posted in the rooms. C
99 Industry representatives give presentations
on safety.
C
100 Tours are taken of other factories plants as
part of safety instruction.
NC No Tours are taken
101 Industry representatives make safety
inspections of the lab/classroom. (AYES,
ASE, AGC, ABC, KCIEC)
C
102 Staff and staffs receive hazardous
communication training at the beginning of
each industry term.
C



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Accidents
101 Adequate accident statistics are kept. C
102 Accidents are reported to the proper
administrative authority.
C
103 A copy of each accident report is filed with
the appropriate authority.
C
104 Accident reports are analyzed for
instructional purposes and to eliminate
hazards.
C
105 The industry has a written hazardous
communication program.
C
106 The industry maintains an up-to-date MSDS
file.
NC File was not found
up to date.
107 Emergency numbers, such as 911 and fire
and police department numbers are posted in
the appropriate location.
C



Audit Summery
Audited Department 04
No of Auditors 12
No of Good Areas ( Conformity) 88
No of Bad Areas (Non conformity) 07
No of Partial Conformity 02

Good Areas: Walton very much very conscious about Environmental,
Occupational health & Safety Management System. It has established individual
Fire safety team to prevent any kind of fire related damages. A self-dependent
hospital has been established for preventing accidental issue. Whole areas are
posted various types of Safety Instructions. All type of indications are marked all
over the factory. It has taken a lot of training and awareness program to create skill
and awareness among employees. It can be said easily that Walton Hi-tech

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Industries has set up a strong Environmental, Occupational health & Safety
Management System.
Related Picture:

Different Types of Safety Awareness Posters Signs are displayed all over the factory.


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Instructions are displayed where safety Items are necessary to use.



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Using Safety Hand gloves, Ear Plug & shoe




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Safety is first Priority




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Fire Extinguisher Indications are marked on the floor.


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Fire Fighters are on duty on various parts of the factory.




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Fire Extinguisher Sign are highly highlighted(easily visible)



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Bad Areas: During the audit some nonconformity also found such as no training
programs were arranged for the newly appointed employees and MSDS file were
not found up to date. Tour program should be taken to another factory to acquire
mass knowledge about safety management system.

Recommendations for Non-conformities
No. NC Suggestion
1 Some employees are found
who do not use of proper types
of extinguishers for various
fires.
They should take initiative action for the
new employees to provide training on
different type of fire.
2 In Refrigerator-2 Production
department one switch was not
working properly.
Maintenance Department should be more
careful to work according to check list.
3 In Motorcycle chassis
department one found washing
motorcycle using cloth instead
of brush
To keep the standard monitoring should
be increased.
4 In most of the department tools
were not found clean.
Supervisors should be more careful
regarding this issue.
5 Printed safety rules are not
given to each staffs.
Printed safety rules should be given to
each staffs immediately.
6 Tours are taken of other
factories plants as part of safety
instruction.
They should have regular visit in other
factories to acquire more knowledge on
safety related issue.
7 MSDS file were not found up
to date.
The industry should maintain an up-to-
date MSDS file.


MR Comments: Management Representative who also Part of audit team
promised to remove all type of non-conformities within short period. It might take
02 weeks.


Conclusion: I am very much glad to be a part of this internal Audit team. I learnt a
lot safety related issues during this audit. Again, I would like thank my honorable
course teacher to such type of learning topic as part of our study.

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Appendix:

1. Class note of Dr. Md. Mamunur Rashid
2. Book: Industrial Safety & Health by Dr. Md. Mamunur Rashid
3. Different web sources for Safety Audit related report
4. Environmental, Occupational health & Safety Management of WHIL