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Prepare the audit around the worksite
Define the audit’s scope before starting. Identify the areas, shifts, jobs, equipment, materials, vehicles, contractors, and temporary workers to include. Plan how to cover maintenance, storage, warehousing, and tasks that happen only during shutdowns, startups, or other unusual conditions.
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Review relevant information before the walkthrough, and ask workers who know the work where hazards arise and how controls can fail. Useful records and references include:
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- Prior inspection findings and whether corrective actions were completed.
- Injury and illness records, hazard reports, complaints, and incident or near-miss investigations.
- Job hazard analyses and existing safety and health programs.
- Equipment manuals, Safety Data Sheets, exposure assessments, and records of process or equipment changes.
OSHA describes hazard identification as an ongoing process, not a one-time exercise. Its Hazard Identification and Assessment guidance and Job Hazard Analysis guidance can help frame the review.
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Walk the site and observe work
Inspect operations, equipment, work areas, facilities, plant vehicles, and transportation vehicles. Include worker participation and observe how tasks are performed, not just whether a written procedure exists. OSHA recommends regular inspections and provides sample inspection checklists; those are prompts to adapt, not a universal pass/fail form.
Use a site-specific checklist to prompt attention to housekeeping; slips, trips, and falls; electrical hazards; equipment operation and maintenance; fire protection; workflow and work organization; work practices; workplace violence; ergonomics; and emergency procedures. Add prompts for the hazards and activities particular to the facility. Document observations clearly; photos or video can help explain a condition and later confirm that it was addressed.
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- Vehicle inspection report book helps document and report needed repairs to help maintain safe workplace utility vehicles.
- Heavy equipment inspection report contains a checklist of 36 common vehicle items and space for additional comments. Easy to use for reporting vehicle condition.
- This equipment maintenance log book set comes with 25 books. Each book contains 31 sets of forms. In total, you will receive 775 forms.
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Check machinery and hazardous-energy controls
Machine guarding
Look for exposure to ingoing nip points, rotating parts, flying chips, and sparks. For each guard, consider whether it is suitable for the hazard, firmly attached, in good condition, and positioned so workers cannot reach the danger zone. Check point-of-operation protection and whether fixed machinery is securely anchored. OSHA’s sample checklist includes questions about contact with dangerous moving parts, secure guards, and objects falling into moving machinery. Use the applicable machine-guarding requirements for the equipment being inspected.
Lockout/tagout and servicing
For servicing and maintenance, review the hazardous-energy-control program and compare written procedures with the work performed. Check that procedures address the equipment and energy sources in scope, isolation and verification steps, and the responsibilities of affected and authorized workers. Review role-appropriate training, periodic inspections, correction of deficiencies, and the required certification records.
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- 2024 OSHA Construction Safety Book is the seventh edition with the new OSHA HazCom final rule on 5/20/24. While the rule takes effect 7/19/24, the compliance dates don’t begin until 1/19/26 per 29 CFR 1910.1200(j).
- Construction Site Book offers quick access to essential OSHA regulations, jobsite hazards, and practical safety tips. It also helps employees identify hazards and prevent injuries and illnesses.
- Features easy-to-read format, full-color images, chapter quizzes with answer key, and comes in a compact size making it a convenient reference for employees.
- Critical topics include Confined Space Entry; Cranes & Derricks; Electrical Safety; Emergency Response; Ergonomics & Back Safety; Excavations; Fall Protection; First Aid & Bloodborne Pathogens; HazCom; Health & Wellness; Jobsite Exposures; Lockout/Tagout; Ladders & Stairways; Materials Handling/Storage; Motor Vehicles; PPE; Scaffolds; Site Safety & Security; Slips, Trips & Falls; Tool Safety; Welding, Cutting & Brazing; and Work Zone Safety.
- Specifications: 5 1/4” x 7 1/4", English, Soft bound. 7th Edition. Copyright 2024.
OSHA’s lockout/tagout enforcement instruction describes periodic inspection requirements, including an inspection at least annually by an authorized employee other than the employee using the procedure being inspected. Confirm the current standard and how it applies to the particular operation rather than treating a checklist prompt as a substitute for that review.
Assess health exposures and changing conditions
Not every hazard can be found by looking around. Chemical, physical, biological, and ergonomic exposures may require records review, exposure monitoring, an industrial-hygiene assessment, or review of medical trends. Consider whether changes to equipment, materials, processes, workstations, or workflow have introduced new risks or made existing controls inadequate.
OSHA’s 29 CFR 1960.26 addresses inspections in federal-agency occupational safety programs. Its specific inspection-conduct rule should not be generalized to every private employer; determine which requirements apply to the workplace and jurisdiction being audited.
Document findings and verify corrections
For each finding, record enough detail to identify the location, task, hazard, people potentially exposed, and relevant evidence. Review injuries, illnesses, near misses, complaints, and recurring patterns for root causes or weaknesses in controls—not only the immediate defect.
- Assess the seriousness of the potential harm and the likelihood of exposure.
- Apply interim protection where needed while a lasting correction is arranged.
- Assign a corrective action to a responsible person and set a practical completion point.
- Verify that the correction controls the hazard; document the follow-up and address any remaining risk.
When it is safe and feasible, correct straightforward issues such as housekeeping or trip hazards when they are found. OSHA’s hazard-identification guidance and job hazard analysis guidance support identifying hazards, involving workers, and following through on controls.
Use a checklist as a prompt, not a compliance certificate
OSHA does not prescribe one universal industrial-audit checklist or scoring scale for every workplace. A useful audit connects program and record review with a hazard-focused walkthrough, direct observation with worker interviews and any needed measurements, and routine work with emergency and nonroutine tasks. A completed form alone does not establish that every hazard or applicable requirement has been addressed.
This is a general U.S. workplace-safety overview, not legal advice or a complete compliance checklist. Requirements depend on the industry, work process, hazards, and jurisdiction. Identify the standards relevant to the site, including OSHA’s standards and regulations, and adapt the inspection to the work being done.
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