Manufacturing & Plant Safety: Checklist Template

1. Walking & Working Surfaces 7 items

Are all aisles and walkways clearly marked with yellow floor paint? Yes / No 15 pts
Are floors free of oil, grease, water, or chemical spills? Yes / No 30 pts
Are all "Trip Hazards" (cords, hoses, debris) removed from traffic zones? Yes / No 20 pts
Are stairs equipped with secure handrails and anti-slip treads? Yes / No 15 pts
Are mezzanine edges protected by standard guardrails and toe-boards? Yes / No 25 pts
Are floor gratings and drain covers secure and flush with the floor? Yes / No 10 pts
Floor Maintenance Level: Rating
- Clean/Clear 20 pts
- Minor Clutter 10 pts
- Hazardous/Slippery 0 pts

Are all rotating parts (belts, pulleys, shafts) fully enclosed? Yes / No 50 pts
Are point-of-operation guards in place to prevent hand entry? Yes / No 50 pts
Are "E-Stop" (Emergency Stop) buttons accessible and clearly marked? Yes / No 40 pts
Do machines remain de-energized if a guard is removed? Yes / No 45 pts
Are foot pedals protected against accidental activation? Yes / No 20 pts
Is there sufficient clearance between machines for safe operation? Yes / No 15 pts
Are splash guards installed on machines using coolants or lubricants? Yes / No 10 pts
Machinery Safety Status: Rating
- Fully Guarded 40 pts
- Missing/Damaged Guards 15 pts
- Immediate Danger 0 pts

Is a written LOTO procedure available for every machine? Yes / No 30 pts
Are employees using individualized locks and "Danger" tags? Yes / No 50 pts
Is there a designated station for LOTO hardware and logs? Yes / No 20 pts
Are "Energy Source" labels applied to all disconnect switches? Yes / No 25 pts
Do employees perform a "Try-Out" to verify zero energy? Yes / No 40 pts
Are annual LOTO inspections/certifications up to date? Yes / No 30 pts
LOTO Program Discipline: Rating
- 100% Compliance 40 pts
- Administrative Gaps 20 pts
- Critical LOTO Failure 0 pts

Is a 36-inch (91cm) clear space maintained in front of all panels? Yes / No 30 pts
Are all junction boxes and panels closed and free of exposed wires? Yes / No 35 pts
Are extension cords prohibited for permanent equipment power? Yes / No 20 pts
Are Ground Fault Circuit Interrupters (GFCI) used in wet areas? Yes / No 25 pts
Are electrical rooms/closets free of combustible storage? Yes / No 25 pts
Are disconnects clearly labeled for the equipment they control? Yes / No 15 pts
Electrical Hazard Rating: Rating
- Low Risk/Code Compliant 25 pts
- Blocked Panels/Damaged Cords 10 pts
- Fire/Shock Hazard 0 pts

Are daily pre-start inspection checklists completed for every lift? Yes / No 25 pts
Are operators carrying valid certification cards? Yes / No 30 pts
Are backup alarms and strobe lights fully functional? Yes / No 20 pts
Is the charging station equipped with an eyewash/shower? Yes / No 35 pts
Are forks kept lowered and tilted back when traveling? Yes / No 15 pts
Is the load capacity plate legible and never exceeded? Yes / No 20 pts
Are pedestrians keeping a safe "3-foot" distance from active lifts? Yes / No 25 pts
PIT Safety Behavior: Rating
- High Discipline 25 pts
- Poor Driving/No Inspection 10 pts
- Critical Unsafe Operation 0 pts

Are all containers (including secondary) clearly labeled? Yes / No 25 pts
Is the GHS-compliant Safety Data Sheet (SDS) binder accessible? Yes / No 20 pts
Are flammable liquids stored in a grounded, fire-rated cabinet? Yes / No 40 pts
Is secondary containment used for all bulk liquid storage? Yes / No 30 pts
Are eyewash stations tested weekly and records maintained? Yes / No 20 pts
Is a spill kit available and fully stocked for the chemicals used? Yes / No 15 pts
Chemical Management: Rating
- Fully Secured 30 pts
- Minor Labeling Errors 15 pts
- Uncontrolled Leak/Risk 0 pts

Are cylinders stored upright and secured with chains/straps? Yes / No 30 pts
Are valve protection caps in place when not in use? Yes / No 20 pts
Are Oxygen and Fuel gases separated by 20ft or a fire wall? Yes / No 25 pts
Are "Empty" and "Full" cylinders stored separately? Yes / No 10 pts
Are gauges and hoses free of leaks and dry rot? Yes / No 20 pts
Cylinder Safety: Rating
- Correct Storage 20 pts
- Unsecured/Miscapped 10 pts
- High Explosion Risk 0 pts

Is safety eyewear (Z87.1) worn by everyone on the floor? Yes / No 40 pts
Is steel-toed footwear mandatory and in use? Yes / No 30 pts
Are earplugs or muffs worn in designated "High Noise" zones? Yes / No 25 pts
Are gloves appropriate for the specific hazard (cut/chemical)? Yes / No 20 pts
Is respiratory protection (N95/Half-mask) worn where required? Yes / No 30 pts
Are "No PPE, No Entry" signs posted at all plant entrances? Yes / No 10 pts
PPE Culture: Rating
- 100% Enforcement 30 pts
- Sporadic Compliance 15 pts
- Negligent 0 pts

Is the rated load capacity clearly marked on the bridge/hoist? Yes / No 25 pts
Are daily pre-use inspections logged by the operator? Yes / No 20 pts
Does the "Dead-Man" switch on the pendant function correctly? Yes / No 30 pts
Are lifting slings/chains inspected for nicks, stretches, or wear? Yes / No 35 pts
Is the safety latch present and functional on the hook? Yes / No 20 pts
Lifting Operations Quality: Rating
- Safe/Inspected 25 pts
- Minor Wear Noted 12 pts
- Critical Hardware Fail 0 pts

Are fire extinguishers inspected monthly and within 75ft travel? Yes / No 30 pts
Is the sprinkler system clear of storage (18-inch rule)? Yes / No 25 pts
Are exit doors unlocked and swinging in direction of travel? Yes / No 50 pts
Are "EXIT" signs illuminated and visible during power failure? Yes / No 20 pts
Is the First Aid/Trauma kit stocked and accessible? Yes / No 20 pts
Are evacuation maps current and posted in every department? Yes / No 15 pts
Emergency Readiness: Rating
- Mission Ready 30 pts
- Minor Obstractions 15 pts
- Blocked Exits/Risk 0 pts

Is combustible scrap (cardboard/wood) removed daily? Yes / No 15 pts
Are oily rags stored in lidded, self-closing metal cans? Yes / No 25 pts
Is the plant floor swept and free of metal shavings/dust? Yes / No 10 pts
Are tool shadows or racks used to keep the area organized? Yes / No 10 pts
Is external dumpster area clean and lids closed? Yes / No 5 pts
5S / Housekeeping Rating: Rating
- World Class 15 pts
- Standard 7 pts
- Unorganized/Dirty 0 pts
Plant Manager Final Review & Critical Action Items: Comments