How to use this checklist: walk one area at a time. Mark each item Pass, Fail, or N/A. Every Fail gets a note, a photo if possible, an owner, and a due date. Items are generic best practice, add rows for hazards specific to your processes, and remove areas that don't apply.
Housekeeping
- Aisles and walkways clear, marked, and unobstructed
- Floors dry; spills cleaned immediately; anti-slip surfaces intact
- Materials stacked stable and below safe height limits
- No accumulation of combustible dust, scrap, or packaging
- Waste containers emptied on schedule; oily rags in covered metal containers
- Lighting adequate and functional in all work and transit areas
Electrical
- Clear access (36 in / 90 cm minimum) maintained at all electrical panels
- Panel covers, knockouts, and junction box covers in place
- Cords free of damage, splices, and taped repairs
- Extension cords not used as permanent wiring; no daisy-chained power strips
- GFCI protection in wet or damp locations and tested
- Circuits labeled; only qualified persons access energized equipment
Machine guarding
- Point of operation guarded on every machine that exposes hands to injury
- Belts, pulleys, chains, gears, and rotating shafts fully enclosed
- Interlocked guards stop the machine when opened (function-tested, not assumed)
- No guards removed, bypassed, taped, or jumpered
- Fan blades below 7 ft guarded with openings no larger than 1/2 in
- Fixed machines anchored; emergency stops reachable and functional
Personal protective equipment (PPE)
- PPE hazard assessment current for each job or area
- Required PPE actually in use (eyes, ears, hands, feet, head as assessed)
- PPE in serviceable condition, no cracked lenses, torn gloves, compressed earmuffs
- Replacement stock available at the point of use
- Signage matches actual PPE requirements for the area
Emergency egress and fire
- Exits marked, illuminated, unlocked from inside, and unblocked
- Exit routes clear along the full path, not just at the door
- Fire extinguishers mounted, charged, accessible, and inspected (tags current)
- Alarm system functional and audible over production noise
- Emergency lighting tested; assembly points posted and known
- Sprinkler heads unobstructed (18 in / 45 cm clearance)
Chemicals
- All containers labeled, including secondary and transfer containers
- Safety data sheets accessible to every shift that uses the chemical
- Incompatible chemicals stored separately; flammables in rated cabinets
- Eyewash / safety shower within reach of corrosive use areas, flushed on schedule
- Ventilation functioning where required; spill kits stocked
- Chemical inventory current, nothing unlabeled, orphaned, or expired
Ergonomics
- Heavy or frequent lifts between knee and shoulder height where possible
- Mechanical aids (hoists, carts, lift tables) available and used for heavy loads
- No sustained awkward postures, twisting under load, overhead reaching
- Workstation heights appropriate to the task and adjustable where practical
- Anti-fatigue matting at long-duration standing stations
- High-repetition tasks rotated or paced to limit exposure
Follow-up log
| # | Area | Finding | Risk (S x L) | Owner | Due | Verified closed |
|---|---|---|---|---|---|---|
| 1 | ||||||
| 2 | ||||||
| 3 | ||||||
| 4 | ||||||
| 5 |