Professional Documents
Culture Documents
Confined Spaces
Checkpoints Level 1:
1.1. Risk Assessment, SOP & OPL:
Overall SOP describing the confined Spaces program available?
SOP must comply with VPO procedure (inventory / risk assessment / controls / atmospheric
monitoring / signalization / work permit requirements / emergency response (stand by employee
requirements) / training requirements) and must include how to ensure safety contractors .
1.2. Atmospheric monitoring
Portable multi-gas air monitors available / calibrated / OPL for use / used for all confined spaces
access / operators trained and familiar with operating the meters levels.
1.3. PPE (Personal Protective Equipment) and CPE (Collective Protective Equipment)
Are PPE and CPE available / used to allow safe entry, safe works, safe exit and safe escape (in case
of emergency)?
1.4. Execution Check
Can the employees explain the basics of confined spaces entry?
Checkpoints Level 2:
2.1. Work Permits
Used for all Confined Spaces. events? / include all required information?
2.2. Inventory of Confined Spaces
Available? Complete?
2.3. Training
For all employees that enter confined spaces or manage those who enter confined / training records
available? Content ok?
Checkpoints Level 3:
3.1. Legal
Has the applicable local legislation been identified and interpreted by the ES department?
3.2. Risk Assessment / SOP & OPL
Are there a SOP/OPL for each confined space (or group of confined spaces) describing: Specific
hazards of the confined space / Pre-entry cleaning requirements / The confined spaces entry and
exit procedures / Clear link with the applicable Lock - Tag -Try procedures / Adequate isolation of the
confined space / De-energization of all moving parts inside the confined space / Requirements for
(electrical) tools used inside the confined space / Means of communication / The use of atmospheric
monitoring equipment / Stand-by employee requirements / PPE and CPE requirements / Work
Permit requirements / Detailed rescue plan
3.3. Responsibilities - RACI ?
RACI describing the Roles and Responsibilities for the confined spaces entry available?
3.4. Signalization - Are all confined spaces marked / labeled? (Checkpoints Level D:
Checkpoints Level 4:
4.1. Risk Assessment / SOP & OPL Process to identify temporary confined spaces during contractor works, excavations etc.
4.2. Execution Check - Can each trained / authorized employee explain in detail the confined space
SOP / practices?
4.3. Process to check compliance with the confined space SOP , including work permits? Feedback to
operators when errors ?
4.3.. Execution Check - Can each contractor explain the basics of confined spaces entry?
Checkpoints Level 5:
5.1. Organizational - Human factors
Are human factors / physical and mental capabilities) consider before allowing access to confined
spaces? (general health condition, claustrophobia, hero mentality, fatigue,) via the work permit or
last check?
5.2. Training Emergency procedures
Emergency procedures for confined space rescue been exercised in practice at least yearly?
5.3. Maintenance / inspection
Maintenance work orders / SWI that require confined space entry linked with spec confined space
SOP/OPL
5.4. Maintenance / inspection
Planned inspection / maintenance for all working at height equipment (except PPE) managed via a
preventive maintenance work order system ( SAP or other)?
3.2. Signalization
All Working at Heights equipment properly labeled / indicating that the equipment is fit for use?
3.3. Maintenance
Maintenance scheme for all height access equipment?
3.4. Storage
Working at Height equipment stored in a limited number of designated storage areas / in accordance
with manufacturers specifications?
3.5. Legal
Has the applicable local legislation been identified and interpreted by the ES department?"
Checkpoint level 4
4.1. Risk assessments
Explain Working at Heights Priority Setting matrix
4.2.. Risk assessments
Risk assessments done for maintenance / inspection tasks at elevated equipment (example motors
of agitators on tanks) that is not safely accessible (no platform with guarding installed) / are these
risk assessments linked to the work orders?
Checkpoint level 5
5.1. Maintenance /inspection
Planned inspection / maintenance for all working at height equipment (except PPE) managed via a
preventive maintenance work order system ( SAP or other)?
2. Working at height - Basics check
Checkpoint level 1
1.1. Execution check
Are employees or contractors observed working near abysses of more than 2 m (6,5 feet) without
using a safety harness /lifeline? Only double lanyards used (unless risk assesment shows that single
lanyards are acceptable)?
1.2. All Working at Heights equipment in good working condition?
Checkpoint level 2
2.1. Platform guarding installed at all platforms / complying to VPO standards
2.2. Execution Check
Can employees explain the basics of working at heights safety?
Do employees follow the Working at Heights procedures and do they use Working at Heights
equipment safely?
2.3. Execution check
Can contractors explain the basics of working at heights safety?
Do Contractors follow the Working at Heights procedures and do they use Working at Heights
equipment safely? Contractors are not allowed to use ABI Working at Heights equipment without
written permission from ABI
Checkpoint level 3
3.1. Fix ladders in the facility comply with the VPO standards
3.2. All defective equipment appropriately segregated, stored and tagged?
Checkpoint level 4
4.1. Small mobile steps with more than 2 steps equipped with a handrail
4.2. The first and last step of every stair clearly marked and are sings "use handrail" present?
Checkpoint level 5
5.1. The proper use of handrails is implemented in the facility.
Observe behavior during audit. If 1 manager or if > 2 employees are not using handrails during
audit, the score of this question must be ZERO
5.2. Facility has at least 1 mobile platform to allow safe cleaning practices and to allow safe basic
maintenance tasks at height?
3. Working at heights - Roofs
Checkpoint level 1
1.1. Roof inventory
Available, classifying safe and unsafe roofs?
1.2.. Access to roofs
Access to roofs managed as per VPO procedure(for Safe Roofs: SOP / OPL for routine tasks / for
Unsafe Roofs: Work permit)
1.3. Works on roofs itself
All works on the roofs itself (such as repairs, changes on structure, bitumen works etc..) managed by
a safety plan + method statements + work permits?
1.4. Works on equipment on roofs
All works on equipment on the roofs (except for routine tasks) managed by a safety plan + method
statements + work permits?
1.5. Safety plants and method statements for works on unsafe roofs validated by ZBS department?
1.6. Execution check:
Can employees explain the basics for access and works on roofs?
1.7. Execution check:
Can contractors explain the basics for access and works on roofs?
1.8. Permanent safety supervision ON the roof during all works on unsafe roofs?
Checkpoint level 2
2.1. Signalization
All unsafe roofs marked with signage (at all access points)
2.2. Access to unsafe roofs
All access points to unsafe roofs (ladders, stairs, doors, windows) locked?
describes how the keys are managed?
Checkpoint level 3
3.1. Skylight protection
Are all skylights protected so that fall hazards are eliminated?
Checkpoint level 4
4.1. Lifelines / Anchor points
Lifelines and / or anchor points installed on all unsafe roofs?
4.2. Lifelines / Anchor points - certification
Lifelines and anchorpoints are certified?
4.3. Maintenance / inspection
Planned inspection / maintenance
system ( SAP or other)?
for roofs
Checkpoint level 5
5.1.Management of change new roofs
VPO requirements of Annex 7 of VPO.SAFE.3.1.02.Working at Heights, SAFETY REQUIREMENTS FOR
NEW ROOFS implemented for new roofs and major upgrades existing roofs
5.2. Maintenance / inspection
Drones used for inspection of roofs?
5.3. Suport permanent safety supervision via technology
Drones or cameras used to support the permanent safety supervision during works on unsafe roofs?
4. Working at heighs - Scaffolding
Checkpoint level 1
1.1.Execution check
Installed scaffolding complying with the VPO requirements?
1.2. Execution check
Scaffolding users work safely?
Checkpoint level 2
2.1. Signalization
Are all scaffoldings tagged with an inspection tag at all times?
Checkpoint level 3
3.1.Installation
Scaffolding designed, erected, altered, moved and dismantled by competent people, / all scaffolding
work under the supervision of an accredit expert?
Checkpoint level 4
4.1. Inspection
Is scaffolding approved by an accredit expert prior to use, during use (at least weekly) and after
each substantial alteration?
Checkpoint level 5
5.1. Installation
Safety plan describing the safe working practices to erect, alter, move and dismantle scaffolding
provided by the accredit expert and is it approved by the plant ES department
5.2. Risk Assessment , SOP & OPL
Owned scaffolding systems have a SOP/OPL (operating limits, the operating/safety instructions and
required inspections). Not applicable if no own scaffolding on site.
5, Working at heights Safe Access to conveyers
Checkpoint level 1
1.1. Execution check
Employees can explain safe practices to access conveyers and no unsafe acts observed
Checkpoint level 2
All lifting equipment properly labeled / indicating the maximum load / indicating that the equipment
is fit for use?
3.3. Maintenance
Maintenance scheme for all lifting equipment? The maintenance is done by a qualified employee or
contractor? Is done at least yearly?
3.4. Legal
Has the applicable local legislation been identified and interpreted by the ES department?"
Checkpoint level 4
4.1. Risk assessments
In-depth risk assessment is done for lifting activities in the following areas
BTS: lifting of agitators , mixers and aerators
Brew house: lifting of filter plates of wort filters
Score Non Applicable if no BTS and no wort filters
Checkpoint level 5
5.1.Risk Assessment
A risk assessment done to identify where safe anchor points / fix lifting equipment must be put in
place in order to allow safe and ergonomic lifting practices for maintenance purposes (example:
above heavy motors, above large manifolds etc.)
5.2.Maintenance /inspection
Planned inspection / maintenance for all lifting equipment, anchor points, racks and shelves are
managed via a preventive maintenance work order system ( SAP or other)?
2. Lifting Equipment Basics Check
Checkpoint level 1
1.1. Execution check
No employees or contractors observed working with defective lifting equipment or lifting equipment
that is not fit for purpose? (check tag, pre-check before use, appropriate for lifting of persons).
2.2. Execution check
Lifting equipment and anchor points in good working order?
2.3. Execution check
No use of cranes nearby powered overhead electrical power lines (forbidden unless the power line
area is properly screened off)?
Checkpoint level 2
2.1. Execution check
Is the area where the lifting takes place properly protected so that nobody can enter the danger
area?
2.2. Execution check
Is the lifting equipment set up and used on firm surfaces?
2.3. Execution Check
Can employees explain the basics of working with lifting equipment?
Do employees follow the procedures to work with lifting equipment and do they use lifting
equipment safely?
2.4. Execution check
Can contractors explain the basics of working with lifting equipment safety?
Do Contractors follow the procedures to work with lifting equipment and do they use lifting
equipment safely? Contractors are not allowed to use lifting equipment without written permission
from ABI
Contractors are not allowed to use a cranes without valid certification
Checkpoint level 3
3.1. All defective equipment appropriately segregated, stored, and tagged?
3.2. Lifting equipment that is not in use is stored appropriately in designated area (5S), in
accordance with the manufacturer's specifications?
3.2. Home- made systems are approved in writing by an accredited expert?
3.3. Are FLT used to lift anything other than pallets? During walk through, check whether any forklift
trucks are used to lift goods other than pallets. If so ensure: proper attachments are used,
slings/hoist belts are protected from damage by the forks, respect of load limits of slings/hoist belts,
proper attachment of the slings/hoist belts to prevent slip from the forks.
Checkpoint level 4
4.1. Racks
The posts / columns of racks are properly protected?
4.2. Maintenance - Racks
All racks and shelves are inspected at least yearly?
4.3. Signalization - Racks
Are all racks and shelves tagged with the maximum load?
4.2.. Access
Are all electrical systems accessible for control and maintenance with proper lighting (no blocked
cabinets).
4.3. Maintenance / inspection
Is inspection of equipment performed as specified in the VPO procedure? Records are available.
4.4. Electrical schemes
A list or scheme of all electrical panels available (number, location, voltage, supply)
4.5. Electrical hand tools
Electrical hand tools at least checked yearly. Inventory, checklist and records available
Checkpoints Level 5
5.1. Electrical schemes - process
Evidence that there is a process in place and are resources allocated to ensure up-to- date,
electrical diagrams of all electrical panels (and their interconnections) These electrical diagrams
must comply with the local standards. If no local standards are available, they must apply to
international standards (ICE / ISO / ANSI).
source).
5.2. Environmental factors
Evidence that electrical equipment is appropriate for the environment (temperature, humidity, dust
presence) in which they are put into service.
5.3 Maintenance / inspections
Are the repairs of all findings of inspections on electrical equipment scheduled in the maintenance
schedule?
5.4. Maintenance/ Inspection
Planned inspection / maintenance
for all electrical equipment managed via a preventive
maintenance work order system ( SAP or other)?
5.5. Fire prevention high-voltage cabins and transformer lodges:
Automatic fire detection by means of smoke detectors at the ceiling and in the raised floors must be
installed andhigh-voltage cabins must be a building separated from all other buildings or must be a
fire-proof cut-off.
5.6.. All aboveground cabling is put into proper cable runs
Employees explain what measures are in place (technical , procedural , behavioral) to avoid
explosions in their area.
2.3. Execution Check
Maintenance employees explain what measures are in place (technical , procedural , behavioral) to
avoid explosions when doing maintenance in areas with potential explosive atmosphere.
2.4. Execution Check
Contractors (including truck drivers if applicable) explain what measures are in place (technical ,
procedural , behavioral) to avoid explosions in their area.
Checkpoint level 3
3.1. Risk Assessment
Classification of explosion hazardous zones in accordance with the local legislation or VPO
3.2. Signalization
Zones with potential Explosive Atmosphere marked
3.3. Technical status natural gas and biogas
Compliance with requirements of Annex 1 of
natural gas and biogas
3.4. Technical status Hydrogen gas (bottle washers and battery charging units)
Compliance with requirements of Annex 1 of VPO.SAFE.3.1.05.Explosion and Fire Prevention for
Hydrogen gas (bottle washers and battery charging units)
3.5. Technical status bulk loading stations of LPG (Pit stops)
Compliance with requirements of Annex 1 of VPO.SAFE.3.1.05.Explosion and Fire Prevention for bulk
loading stations of LPG (Pit stops)
Compliance with requirements of Annex 1 of
natural gas and biogas
for
Checkpoint level 4
4.1. Risk Assessment
Risk assessment does comply with all minimum requirements of VPO
4.2. Training
All employees (including contractors) having access to EA areas or that are operating related
equipment must be properly trained in the general principles (including the causes) of dust and gas
explosions /the specific risks of the concerned products and equipment / the meaning and
consequences of the explosion hazardous zones classification and the signalization / the measures
put in place to prevent dust and gas explosion and the specific functions of those measures.
Trainings recorded.
Checkpoint level 5
5.1. Maintenance/ inspection
Proof that explosion prevention equipment and measures inspected at least yearly
5.2.Risk Assessment
Risk assessment done for all changes to equipment in zones with potential for explosive atmosphere
upfront
5.3. Maintenance / Inspections
Planned inspection / maintenance / calibrations for all equipment that is installed for explosion
prevention managed via a preventive maintenance work order system ( SAP or other)?
2. Explosion and fire prevention Pressure vessels
Checkpoint level 1
1.1. Risk Assessment
Risk assessment to identify the pressure vessels and the process vessels that are put under pressure
(or can be put under pressure accidently) in a certain phase of the process, in order to define the
proper measures for explosion prevention, limiting damage and emergency response.
Checkpoint level 2
2.1. Inventory
Inventory of pressure vessels and Pressure Relief Devices complying to VPO
Checkpoint level 3
3.1. Maintenance / Inspections
Inspections of pressure vessels in compliance with local legislation or VPO procedure
(What vessels need to be inspected, the frequency of the inspections, and the nature of the
inspections)
3.2. Maintenance / Inspections
Inspections and calibration of Pressure Relief Devices in compliance with local legislation or VPO
procedure
Checkpoint level 4
4.1. Training
All employees (including contractors) operating pressure vessels or process vessels that are put
under pressure (or can be put under pressure accidently) in a certain phase of the process properly
trained in The hazards and risks of pressure / pressure vessels and the measures put in place to
prevent explosions of pressure vessels and the specific functions of those measures.
Checkpoint level 5
5.1. Relief Piping
All Pressure Relief Devices equipped with relief pipes that allow safe discharge of the fluid that is
inside the vessel.
5.2. Risk assessment
Risk assessment demonstrates that Pressure Relief Devices are suitable for the tasks
Checkpoint level F
5.3. Maintenance / Inspections
Planned inspection / maintenance / calibrations for pressure vessels and Pressure Relief Devices
managed via a preventive maintenance work order system ( SAP or other)?
3. Explosion and fire prevention Dust Explosion Prevention Safety Management
Checkpoint level 1
1.1. Execution Check
Dust in area at acceptable level / All equipment properly closed to prevent dust escape / electrical
equipment properly closed to avoid dust intrusion
Checkpoint level 2
2.1. Execution Check
Employees of the area and maintenance employees can explain the basic mechanism
explosions
of dust
Safety
4.1. Planning
3 Year plan to bring technical status > 60 % (see VPO.SAFE.3.1.05.02. Annex 3 Dust Explosion
Prevention Safety Management Audit Checklist) or above 90 % if score is higher than 60 %
Checkpoint level 5
5.1. Risk assessment
VPO.SAFE.3.1.05.02. Annex 3 Dust Explosion Prevention Safety Management Audit Checklist:
Total score > 90 % and all blocks > 80 % AND all MUST HAVE questions are OK
5.2. Management of change new equipment
VPO requirements of VPO.SAFE.3.1.05.02. Annex 4 Basic Flow chart dust explosion prevention new
equipment implemented for new and significant upgrades of equipment.
4. Explosion and fire prevention Boilers, Steam and HPHW Safety Management
Checkpoint level 1
1.1. Execution check
Prove that the basic safety controls as described in VPO.SAFE.3.1.05.03. Boilers, Steam and HPHW
Safety Management are done at the requested frequency
Checkpoint level 2
2.1. Execution Check
Boiler operators explain the basic controls done to guarantee safe operation of the boilers
2.2. Self-assessment done via the annex checklist annex of VPO.SAFE.3.1.05.03. Boilers, Steam
and HPHW Safety Management.
Checkpoint level 3
3.1. Risk assessments
Self-assessment formally validated by ZBS ES AND ZBS of the area
Checkpoint level D
3.2..Risk assessment
Annex of VPO.SAFE.3.1.05.03. Boilers, Steam and HPHW Safety Management.
Total score > 60 % and all blocks > 60 % (except for technical status)
Checkpoint level 4
4.1. Planning
3 Year plan to bring technical status > 60 % (Annex of VPO.SAFE.3.1.05.03. Boilers, Steam and
HPHW Safety Management) or above 90 % if score is higher than 60 %
Checkpoint level 5
5.1. Risk assessment
VPO.SAFE.3.1.05.03. Boilers, Steam and HPHW Safety Management::
Total score > 90 % and all blocks > 80 % AND all MUST HAVE questions are OK
5.2. Management of change new equipment
VPO requirements of VPO.SAFE.3.1.05.03. Boilers,
Steam and HPHW Safety Management
implemented for new and significant upgrades of equipment.
4.3. Green Tag (LOTO Work Permits): Used for all LOTO events / include all required information
4.4.. Evidence and proper application of out of service tags and locks on equipment that has no
active or scheduled work.
4.5. List of authorized machine shop tools workers posted or easily retrievable.
Checkpoints Level 5:
5.1. Evidence that a procedure and work permit system is in-place for by-passing a safety device or
system (i.e. fixed guards, interlocks, fire detection systems, gas detection alarms, etc.).
5.2.. Removal of Abandoned Locks
Evidence that an Abandoned Lock Removal Form is used for abandoned locks
5.3 Evidence of monthly audits of LOTO/SAM program requirements.
5.4. Evidence of routine operator checks for missing or broken machine guarding.
5.5. In the event that a SOP does exist, is there an expectation to review the SOP which are older
than 1 year to verify accuracy?
5.6.. Work orders
LOTO procedures linked to work order system
2. SAM & Lock Tag Try Equipment
Checkpoint level 1
1.1. Locks, tags, chains, multiple locking devices, lock boxes, etc. easy available for employee use
when isolating, securing or blocking of machines and/or equipment from energy sources.
1.2. Execution check
All fixed guards/interlocks/light curtains operational and in place ( or temporary measures and signs
in place when defective) No exceptions observed during audit
Checkpoint level 2
2.1. Metal and woodworking machinery in workshops (including temporary workshops for projects)
are locked if not in use
2.2. Locks are personalized (each Authorized person has his own lock & the only key to the lock).
.Checkpoint level 3
3.1. The moving parts of metal and woodworking machines are guarded to protect the operator
from both the moving parts and ejected chips.
3.2. All hot surfaces in areas with frequent access are properly insulated with warning signs.
3.3. A completed risk assessment exist for all machinery that identifies the gaps against the ABInBev machine safety standards.
3.4. The Lockout/Tagout devices are standardized. Lockout and Tagout devices are singularly
identified and are not used for other purposes.
3.5. New equipment
New Equipment Installation comply 100 % with AB-InBev machine safety standards
Checkpoint level 4
4.1. Jog Controls:
Equipment requiring movement of tooling in a powered state to perform specific tasks are equipped
with controls that require 2 hands (for new equipment, for existing equipment 1 hand control is
allowed except for presses and suchlike equipment) to activate the movement of the machine and
an E Stop or Lock Out to secure the machine upon completion of the movement dependent task.
Checkpoint level 5
5. 1. Corrective action plan in place to address the gaps been developed and does it have a
prioritization methodology.
5.2.. All machines and equipment is properly guarded, in accordance with legal and VPO
requirements
5.3. Machine specific Lock-Tag-Try equipment for machines / equipment that requires frequent LOTO.
5.4. Specific color scheme used for Locks ( For new facilities: see VPO procedure.) Personal
(employee) locks / Primary locks (used to affix on energy sources for multiple source lockouts) /
Departmental locks (used to secure lockbox during handover/shift carry over events) / (for new
plants: see VPO procedure)
5.5. Jog Controls: All Equipment requiring movement of tooling in a powered state to perform
specific tasks are equipped with controls that require 2 hands
No exceptions found
No exceptions found
(Any works with risk for the unexpected energization or start-up of machinery and equipment that
are not covered by a clear Lock-Out Tag-out procedure / Any works with risk for the uncontrolled
release of hazardous energy that are not covered by a clear Lock-Out Tag-out procedure / Highvoltage works including any works in the vicinity of high voltage air lines and including any cleaning
activities in transformer rooms / Works on life electrical equipment (See VPO.3.1.04. Electrical
Safety) / Confined spaces entry including any works in areas with risk for oxygen deficiency / Works
on equipment with a risk for exposure to hazardous substances (if not part of the normal work
processes of the plant). A specific line & equipment entry permit must be used for any intervention /
Hot works including repairs / Working at height and near abysses / Use of lifting equipment /
Maintenance / Demolition of asbestos / Demolition works / Excavation works including any such
works nearby underground piping and cables / Perforating of fire walls / Maintenance works on radioactive sources containing equipment)
1.3. Executing check
No main gaps in work permits found that were not identified by the work permit audit system of the
facility.
Checkpoint level 2
2.1. RACI
RACI describing the Roles and Responsibilities with regards to Work Permits program available.
2.2.. Work Permit program covers all required activities of VPO.SAFE.3.1.07.Work Permits
Checkpoint level 3
3.1. Legal
The applicable legislation has been identified and interpreted by the ES department.
3.2. General work permits for contractor works
A valid general work permit is issued for every contractor work, also for works performed by Service
Provider/ in-House Contractors (except for such tasks as office cleaning / restaurant services / FLT
drivers etc. that are covered by the safety plan and part of the daily routine)
3.3. Training
All employees have been trained on the work permit program (Level of detail depends on position of
employee user / non user / authorized persons). Training records available.
3.4. Training
Work Permit system of the facility is part of the induction of contractors and service providers
3.5. Content work permit
The work permits cover the content requirements of VPO.SAFE.3.1.07.Work Permits
Checkpoint level 4
4.1. Execution check
Employees can explain the basics of the work permit program (Level of detail depends on position
of employee user / non user / authorized persons).
4.2. Execution check
Contractors can explain the basics of the work permit program (Level of detail depends on position
of employee user / non user).
4.3. At least 2 copies of the work permit available - with one of the copies available at location where
the work is performed. ( or 1 copy + an up-to-data list of valid work permits available in the
department)
4.4. Duration of a work permit
Evidence that the duration of a work permit is clearly indicated at the work permit and evidence that
the duration of a work permit for a critical tasks (see VPO.3.1.13. Contractor management) is limited
to 1 shift ONLY.
Checkpoint level 5
5.1. Evidence that work permit program is audited at least on a monthly basis (Permit is validated by
an authorized person/Permit identifies the scope of work /All sections are properly completed
(including signatures)/ Persons completing the permit understood the work conducted/Requirements
of work permit are implemented by the persons executing the work/critical tasks validated for one
shift). ES manager is accountable.
5.2. Evidence that
work permit checks are part of the daily safety routines of Plant
Manager/Departmental Manager / Supervisors / ES department / designated AB-Inbev Project
Manager5.2. Duration of a work permit
Evidence of cancellation of the existing permit in the event of a change in hazard, risk or scope .
5.3. Evidence that a specific line & equipment entry permit is used for any intervention on
ammonia and steam (pressurized) equipment. See VPO.SAFE.3.1.08.02.Ammonia Process Safety
Management and VPO.SAFE.3.1.05.03. Boilers, Steam and HPHW Safety Management
5.4. Shift hand-overs
Evidence that a process is in place to ensure that actual permits at shift handovers are formally
checked and handed over with necessary signatures .
5.5. An up-to-data list of valid work permits available in the department.
2. Authorized Employees & Validation
Checkpoints Level 1:
1.1. List
List available that identifies those employees authorized to validate / issue work permits.
Checkpoints Level 2:
2.1. Validation
All work permits for high risks (see list question A.2.) properly validated by the authorized person,
personnel performing the task and a person responsible for the area where the task is done ( or
responsible for the equipment)?
Checkpoints Level 3:
3.1. Validation.
Work permits that are issued for work on live electrical equipment are validated by the Technical
Services or Maintenance manager or his/her delegate
Checkpoints Level 4:
4.1. Use of specialists
Evidence that the authorized person involves specialists if they are not able to do a proper risk
assessment themselves.
4.2. Training
All authorized employees been appropriately trained in the hazards/risks associated with the work.
Training records available.
Checkpoints Level 5:
5.1. Review list
The list of authorized persons is reviewed
Manager/Maintenance Manager and ES Manager.
at
least
annually
and
validated
by
TS
All dosing pumps for hazardous substances using flexible tubes (and all other dosing pumps that
cause a risk for splashes ) must be covered to avoid that employees are splashed by chemicals in
case of leakages. The covers must be built as such that non-compatible products can not become
mixed.
Checkpoint level 5
5.1. Manual dosing
If manual dosing of chemicals in tanks, than technical measures must be put in place to avoid that
the productr splashes out of the tank.
5.2. Chemical discharge
The floors, sewers and discharge piping must be constructed in such a way that discharge of
hazardous substances (CIP, cleaning fluids from bottle washers) is evacuated in a fast and safe
way. CIP rinse installations must be discharged directly into the PROCESS sewer.
2. Hazardous and chemicals management - organisational
Checkpoint level 1
1.1. Risk Assessment / SOP / OPL
Overall SOP describing the Hazardous Substances management must be available
1.2. Inventory
The plant must have a list containing all hazardous substances present on site. The actual MSDS of
all hazardous substances must be available at the plant.
1.3. Compatibility matrix
A matrix table showing the compatibility of the hazardous substances used / stored at the plant
must be available kept up to date and available at the departments
Checkpoint level 2
2.1 .Risk assessment
A risk assessment must be done to assess the risk of all hazardous substances (including biohazards) on site.
2.2 Overview plan
All bulk storages, warehouses and storage rooms of hazardous substances must be indicated on a
site plan or scheme
2.3. Loading/unloading
Unloading and loading of hazardous substances must be completed under the supervision of a
competent AB-Inbev employee (At least at the start and end of the loading / unloading activities)
2.4. RACI
RACI describing the Roles and Responsibilities with regards to the Hazardous substances safety
available
2.5. Executuion check
Storage of hazardous substances is done in accordance with compatibility matrix and requirements
of environmental pillar
Checkpoint level 3
3.1..SOP's/OPL's The necessary procedures for the safe management of hazardous products must be
available. OPLs must be made and posted in order to make these procedures understandable for the
operators.
3.2. Legal
Has the applicable local legislation been identified and interpreted by the ES department?
Checkpoint level 4
4.1. Collective protective equipment regular check
The collective protective equipment is routinely inspected
4.2. Training
All employees who come in contact with hazardous chemicals are properly trained on the risks and
the necessary precautionary measures (control systems/procedures/...). Trainings are recorded.
Checkpoint level 5
5.1 Preventive maintenance
All control measures for hazardous chemicals are assessed for criticality and critical equipment is
included in the site preventive maintenance plan
5.2. Introduction of new chemicals
New hazardous substances (even if only for testing or temporary by e.g. contractors) can not be
used nor stored at the plant unless a clear MOC procedure has been implemented.
3. CO2 safety
NOTE: Check if plant uses Nitrogen (N2) in the process and check if the applicable measures that are
described beneath are implemented (Nitrogen will be included in next update VPO pillar)
Checkpoint level 1
1.1. Risk assessment
Areas where elevated CO2 levels might occur must be identified by means of a risk and CO2
monitoring assessment.
1.2. The areas / locations/ equipment and activities where accidental release of CO2 can lead to
CO2 levels above 5 % are identified and measures are taken to avoid exposure.
1.3. Inventory and identification
All areas where CO2 is present must be inventoried and clearly identified
1.4.Pressure Relief Valves PRV (Safety Valves).
The Pressure Relief Valves (PRV) must be recertified according to local legislation with a maximum
frequency of 5 years and relief pipes must be installed to allow safe relief of overpressure
1.4. CO2 detection
The locations where there is a risk of CO2 exposure must have a fix CO2 detection and alarm system
with clear procedure how to react in case of alarm
Checkpoint level 2
2.1 Training
All operators who work in areas with a risk of CO2 exposure must be trained on the risks of CO2 and
the installed measures.
Checkpoint level 3
3.1. CO2 detection
The CO2 detection is operated, calibrated and maintained according the manufacturers instructions
by trained workers
Checkpoint level
4.1.CO2 detection
A portable CO2 meter (including alarm and able to display the current carbon dioxide concentration
and the 8 hours Time Weighted Average (TWA) value) must be available at each plant.
Checkpoint level 5
5.1. CO2 Concentration Control.
Measures are put in place to keep the CO2 concentration below the permissible CO2 concentration
levels:
Discharge: Technical measures must be taken to avoid discharge of CO2 inside where practicable.
Ventilation: The areas where natural and / or mechanical ventilation must be installed must be
determined on basis of the risk and CO2 monitoring assessment.
4. Ammonia Process Safety Management
Checkpoint level 1
1.1. Routine inspection
Evidence that the Ammoia installation is inspected by the operators based upon a written technical
inspection scheme. Results must be included in a detailed operational logbook
1.2. A system must be in place to ensure that proper legally obliged inspection of other ammonia
equipment is in place (such as pressure control devices, level meters etc). All inspections must be
documented and the findings and recommendations of these inspections must be included in an
action plan
1.3. Work permit
Every routine intervention on the ammonia refrigeration system for which no OPL or SOP exists,
must be preceded by a risk assessment, a method statement and work permit that is validated by
both Plant ES and Utilities manager. For non routine interventions this must be validated by ZBS ES
& ZBS Utilities
1.4.Pressure Relief Valves PRV (Safety Valves).
The Pressure Relief Valves (PRV) must be recertified according to local legislation with a maximum
frequency of 5 years and relief pipes must be installed to allow safe relief of overpressure
1.5. Operator training
The operators in charge of the ammonia refrigeration system must be trained and formally
authorized/certified to run the equipment
1.6.Ammonia detection
The machinery room must be equipped with ammonia
VPO.SAFE.3.1.08.02. Ammonia Process Safety Management
detection
system
according
to
3 Year plan to bring technical status > 60 % (Annex of VPO.SAFE.3.1.08.02.E PSM Ammonia Audit
Checklist) or above 90 % if score is higher than 60 %
Checkpoint level 5
5.1. Risk assessment
VPO.SAFE.3.1.08.02.E PSM Ammonia Audit Checklist:
Total score > 90 % and all blocks > 80 % AND all MUST HAVE questions are OK
5.2. Management of change new equipment
VPO requirements of VPO.SAFE.3.1.08.02 Ammonia Process Safety Management implemented for
new and significant upgrades of equipment.
5. Legionella
Checkpoint level 1
1.1. Inventory:
An inventory of all water cooled Cooling Towers and Evaporative Condensers - CTEC - (even the
smallest) is available.
Each CTEC and companion water system is properly be managed. This includes a proper water
treatment, proper inspection, proper monitoring and proper maintenance.
The water treatment of CTEC must deal with corrosion, scale, fouling and microbiological activity
Checkpoint level 2
2.1 .Inspection of CTEC
Inspections are done according to the table in VPO.SAFE.3.1.08. Hazardous Substances
Checkpoint level 3
3.1..Monitoring of CTEC water systems.
The following monitoring is done:
Water treatment through water parameters .A monitoring schedule must be drawn up and
implemented per water system.
Microbiological monitoring:
o General microbiological condition(TBC): monthly;
o Legionella concentration: see table in VPO.SAFE.3.1.08. Hazardous Substances.
This legionella monitoring must not longer take place if TBC is lower then 10.000 cfu/ml over a
period of 6 consecutive months but needs to start again if TBC exceeds 10.000 cfu/m
Checkpoint level 4
4.1. Cleaning and disinfection process in place for PPE that are put to the disposal of different
persons.
4.2. Employees have proper storage facilities for PPE at their disposal.
4.3. Execution Check
No PPE found lying around non-attended (5S linked).
Checkpoint level 5
5.1. The PPE risk assessment and requirements / PPE matrix are reviewed when changes and at least
a check once a year.
5.2. PPE audits
Evidence of monitoring of the effectiveness of the PPE program by inspection of the equipment and
auditing of compliance to procedures. Managers/supervisors audit for compliance to PPE
requirements in their department using their managers/supervisors checklists (See VPO.SAFE.3.2.2.
Safety monitoring) and document all findings. Offences to the PPE requirements are corrected with
immediately and coaching documented.
Checkpoint level F
5.3. The PPE requirements for every single task are clearly defined (SOP or OPL).
5.4. Evidence of proper follow up of the PPE ZBB Budget.
Evidence that workplace safety risk assessment is done by workgroup, headed by the logistic
manager
3.3. Risk Assessment, SOP & OPL
Evidence that VPO.SAFE.3.1.10.1.Workplace (and) transport safety checklist is used as input for the
workplace safety risk assessment
3.4. Training
All employees (including truck drivers, contractors and visitors) aree trained in the plant traffic rules
including safe pedestrian passages and rules for general plant emergencies.
Visitors and external truck drivers must be informed via flyers and adequate signs. Use symbols
where possible. Training records available.
3.5. Legal
Has the applicable local legislation been identified and interpreted by the ES department?
Checkpoint level 4
4.1 Traffic plan
Detailed traffic plan available, covering ALL the elements described in VPO.3.1.10. Workplace
Transport Safety
4.2. Execution check: Signalization
Well maintained signalization in place to warn for the hazards of workplace transport.
to indicate the maximum speed limit / to indicate the zones where pedestrians are not authorized /
to indicate the traffic routes / to indicate dangerous and vulnerable equipment / to indicate blind
bends / to indicate designated areas such as (un)loading areas / to indicate emergency exits and
equipment / to warn against traffic risk / to indicate parking lots / to indicate maximum allowed
height of vehicles / to indicate one-way systems / to indicate temporary obstacles, potholes etc. / to
indicate the ban on use of electronic devices while driving (at entrance and exit of plant) / To
indicate the mandatory use of seat belts while driving (at entrance and exit of plant) / To indicate
slopes
4.3. Execution check: mirrors
Convex mirrors are in area with obstructed sight, where there is a risk for collision.
(360 - mirrors for crossings where sight to all directions is necessary / 90 or 180 - mirrors for
simple crossings where sight to 1 direction is enough).
4.4. Execution check
External contractors are only allowed to enter the premises with their vehicle to load and unload
equipment. Once this is done, their vehicles are removed from site (exception: designated contractor
areas and proper separated construction sites).
Cones or similar equipment is available at each plant for marking of temporary risk areas.
3.5. Loading and unloading activities
Un)loading activities must only be done in designated, marked areas, away from passing traffic,
pedestrians and others not involved in the (un)loading operations.
Checkpoint level 4
4.1. Execution check
Clear separation between logistic area and the other areas of the facility (signs, barriers,)
4.2. Areas where intense FLT traffic takes place are designated as FLT zones only and NO
pedestrians are allowed unless all FLT drivers in that zone have been informed about the temporary
presence of the pedestrian. These zones are clearly marked.
4.3. Red zones
Special red zones are created in pedestrian free areas if pedestrians have to interfere with FLT
traffic (e.g. for by-products collection or material supply). These zones are clearly marked on the
floor and presence of the operator is indicated via a signal lamp. The FLT do not enter the red zone
when the signal lamp is on.
4.4. Dangerous Zebra Crossings
Dangerous Zebra crossings are colored wit / red in order to emphasis that the pedestrian have no
priority, although it is the designated crossing.
4.5. Gangways near gates
Pedestrian gangways near gates are protected with protective posts aside the gates or by means of
swing doors to avoid pedestrians suddenly to show.
4.6. Picking, sorting and other similar activities
Safe access roads to these areas where picking, sorting and other similar activities take place, are
foreseen for the employees working in these areas (including safe access road to sanitary facilities).
4.7. Stock and sample taking activities
Evidence that specific warning signs are available and used to indicate stock and sample taking
activities in progress.
4.8. AGV paths
The mixing of AGV traffic with manned vehicle traffic and pedestrians is limiedt as much as possible.
AGV paths are marked. Painted lines, arrows, traffic signs etc. are used to identify the route of the
AGV for plant personnel.
4.9. Bicycles and ride-on carts
Bicycles and ride-on carts are not used in warehouse and loading areas except on clearly indicated
bikeways
4.10. Execution check
No personal cars or vans parked on site outside the normal well defined parking lots.
Checkpoint level 5
5.1. Pedestrian gangways
Pedestrian gangways are protected against falling objects when close to goods stacking:
by nets or grids or by pyramidal stacking.
5.2. Access to warehouses
Entrance to warehouses is always enforced via doors next to the gates, NEVER via the gates.
(All new gates must be equipped with a pedestrian door aside, so that pedestrians are segregated
from the other traffic)
5.3. Dangerous crossings
At dangerous crossings, the presence of pedestrians and /or vehicles is indicated by means of sign
lamps / sound / clear marking.
5.4. Parking of trucks in front buildings occupied by people and vulnerable equipment
Trucks are not parked in front of buildings that are likely to be occupied by people (like offices) or in
front of equipment (tanks etc). unless proper barriers are installed to prevent that the trucks
damage the building / equipment if the truck driver does a wrong maneuver.
5.5. Gate safety
Automatic (motorized) horizontal moving gates are equipped with and audible (horn) and visible
(flash light) alarm when closing and opening.
Sectional gates, shutter gates and high-speed type gates must be equipped with fall arrest system
(spring break safety).
Where there is a risk for crossing traffic or where pedestrians are crossing on the other side, a
transparent part (window) must be foreseen.
5.6. FLT inside packaging lines
No FLT are allowed inside packaging lines.
5.7. Safe pedestrians review
Safe Pedestrian Review done if a FLT / pedestrian incident (injury) occurred.
3. Vehicle Safety
Checkpoint level 1
1.1. Inspection
A checklist and OPL is available to allow each FLT, pallet walkie truck and pallet jack driver to check
if the equipment is in good working condition and has been properly maintained before the driver
starts to work with it.
1.2. FLT for working at height
Evidence that FLT are used for working at heights ONLY if a proper working platform(cage), properly
fixed on the mast of the FLT, is used (see VPO.SAFE.3.1.2.Working on heights)
1.3. FLT for lifting of objects other than pallets
Evidence that, for lifting of equipment other than pallets, proper extra lifting equipment is used (see
VPO.SAFE.3.1.3.Lifting Equipment)
Checkpoint level 2
2.1. Inspection & maintenance
There is a preventive maintenance schedule for maintenance of FLT, pallet walkie trucks and pallet
jacks and AGV / ATL
2.2. FLT Driving reverse
FLT must ALWAYS drive in reverse during transport of loads if the view is obstructed by the load
(unless the local conditions make it unsafe to drive in reverse)
To define as of which height the vision is obscured, a clear sign must is on the mast of each FLT and
pallet walkie truck (if load can be lifted)).
2.3. FLT Driving reverse
Evidence that the exact height of the sign DRIVE IN REVERSE if view is obstructed and load is above
this mar on FLT mast is defined based upon a detailed risk assessment for each type of FLT.
Evidence that this risk assessment and the actual height of the sign per FLT are validated by ZBS ES.
Checkpoint level 3
3.1. Parking lot
A dedicated area is foreseen for parking of FLT, pallet walkie trucks and pallet jacks that are not in
use.
3.2. AGV ATL obstacle detection
AGV and ATL are equipped with obstacle detection.
(New AGV must be equipped with 2 level obstacle detection Slow down / Stop)
3.3. Parking on slopes
3.5. Legal
Has the applicable local legislation been identified and interpreted by the ES department?
Checkpoint level 4
4.1 Requirements for FLT
All FLT comply with the minimum requirements of VPO.3.1.10.Workplace Transport Safety and NEW
FLT comply with the minimum requirements for new purchased or leased FLT (as of 01-01-2012), See
annex.4, VPO.SAFE.3.1.10.4. Requirements for new FLT)
4.2. Requirements Ride-on cleaning machines
(new) Ride-on cleaning machines (with driver) comply with the requirements of VPO.SAFE.3.1.10.5.
Requirements for new ride-on Cleaning Machines
4.3. FLT maintenance safety
If FLT are maintained in the facility, a structure to support the forks must be available. Inspection
pits are properly guarded to avoid falls.
Checkpoint level 5
5.1. Maintenance /inspection
Planned inspection / maintenance for FLT, pallet walkie truck and pallet jack a,nd own trucks
managed via a preventive maintenance work order system ( SAP or other)?
4. Driver safety
Checkpoint level 1
1.1. Execution check
All employees and contractors operating a vehicle (FLT / Truck / car,..) are using seatbelt
1.2. Execution check
No use of cell phones & smart phones (exception for hands free devices if allowed by law), Laptop,
Netbooks, MP3, etc. observed while operating a FLT, Truck, Company Vehicle, Leased Vehicle or
Personal Vehicle used for company business, (except for those that are part of the operating
mechanism of the vehicle).
3.4. Legal
Has the applicable local legislation been identified and interpreted by the ES department?
Checkpoint level 4
4.1 Maximum Driving Time Compliance
Maximum driving time in any zone, regardless of local laws, is 12 hours. If for any reason this is
exceeded, an exception report is filed and the driver given at least 12 hours rest time before
beginning the next shift.
(If local laws permit fewer hours, these local laws must be complied with.)
4.2. Telemetry
ALL company owned/leased Tier 1 trucks and dedicated fleet are fitted with telemetry allowing to
monitor speed
4.3. Telemetry - Reports/Monitoring
Systems provide usable reports. Evidence that these reports are reviewed at least monthly and
actions are taken to address findings.
4.4. Alcohol testing
Evidence that the facility does Alcohol testing if allowed by law when drivers enter and leave the
facility and for employees operating vehicles inside the facility
4.5.. Driver certification
Evidence that there is a process in place to ensure that employees (including operating a Company
Vehicle, Leased Vehicle or Personal Vehicle used for company business) have an appropriate valid
drivers license and medical certificate (according local legislation).
(Employees must report any changes in the status of their drivers license (and medical certificate if
applicable) to their manager immediately (e.g. expiration, class change, suspension, revocation or
requirement for special condition).)
4.6. Training
Evidence of yearly refresher training for operators of Trucks , FLT, pallet walkie trucks and pallet
jacks and ride-on cleaning machines. Training records available.
4.7. Execution check
No operation of keyboards (example for WMS on FLT) observed during driving.
(For new installed WMS on FLT and for new FLT the operation of the keyboards must be blocked
unless the FLT is standing still. The information on the displays must however stay available, also
during driving.)
Checkpoint level 5
5.1 Telemetry
ALL company owned/leased Tier 1 trucks and dedicated fleet are fitted with telemetry allowing to
monitor : Speed speed of the truck must be compared to the set speed limit of the highway or road
where the truck is operating / Rapid Acceleration / Rapid Deceleration / Turns at High Speeds / Seat
Belt Use / Idling engine when stopped/ Rest Time System tracks driving time of drivers to verify
within set limits (see above Rest Times
5.2. Commuting training
Evidence that the facility includes
employees.
Checkpoint level F
5.3..Audits and spot checks
Evidence that audits and spot checks are performed to check compliance to ABInBev Safety Driving
rules
5.4. 360 Circle of Safety Vehicle Inspection:
Evidence of 360 Circle of Safety Vehicle Inspection practice.
5.5 FLT without a scratch process
The FLT without a scratch process implemented
5.6. Motorcycle training for commuting
Evidence that ,If allowed by law, the plant organized motorcycle training for all employees using
motorcycles for commuting.
LTI (and the number of days since last LTI), CLTI (and the number of days since last CLTI) and TRI
posted at the entrance of the facility.
Checkpoint level 2
2.1. Training
Employees trained in reporting requirements for Fatality /LTI / CLTI / TRI /Potential Serious Injuries or
Fatalities (SIF) / Incidents / First Aid Injuries (FAI) / hazards/ commuting LTI. Training records
available.
2.2. Induction Contractors and Service Providers
Reporting requirements for Fatality / LTI / CLTI / TRI /Potential Serious Injuries or Fatalities (SIF) /
Incidents / First Aid Injuries (FAI) / hazards part of safety induction process
2.3. Roles and Responsibilities / RACI
RACI describing the Roles and Responsibilities for injury reporting available, including the roles and
responsibilities for the Credit 360 Reporting Tool and Safety Alert communication
3.4. Communication Safety Alerts
Evidence that relevant safety alerts are posted on the visual boards.
Checkpoint level 3
3.1. Up to date data in Credit 360
Fatality / LTI / TRI (including LOST DAYS for LTI)/ CLTI / TRI /Potential Serious Injuries or Fatalities
(SIF) / Incidents / First Aid Injuries (FAI)/ hazards / Commuting LTI up to date on a monthly basis in
Credit 360 reporting tool.
3.2. Legal - Has the applicable local legislation been identified and interpreted by the ES
department?
3.3. Communication safety pyramid
The safety pyramid (hazards / incident / FAI / MTI / MDI / LTI / Fatal and SIF) is part of the visual board
of the plant and of the departments.
3.4. Communication
Evidence that TRI and SIF are reviewed during the daily meeting of the facility
3.5. Communication
Evidence that All injuries and incidents are reviewed in the department during the daily
departmental meeting and the shift hand-over meetings.
3.6. Hazard reporting
Evidence of a sound process of hazard reporting by employees
Checkpoint level 4
4.1. Communication
Evidence that ALL injury notifications for Fatalities, LTI, CLTI and SIF are send out to the stakeholders
within 24 hours by the departmental Manager (or the direct report in case of absence of the
departmental manager).
4.2. Trend Analysis
Trend analysis available, for 3 years and in detail for current year: ( minimum / TRI total (compared
with target) and per department / LTI total (compared with target) and per department / CLTI total
(compared with target) and per department / SIF total (compared with target) and per department /
FAI total and per department/ Incidents total and per department / Hazards total and per
department / SiF per type pareto / TRI per type pareto / FAI pert type pareto / Commuting LTI total
(except NA zone)
4.3. Communication - safety alerts
Evidence that relevant safety alerts are discussed in the safety committee, the departmental
monthly review meeting and the shift hand over meetings.
Checkpoint level 5
5.1. Investigation
Credit 360 Reporting Tool is uses as primary tool for investigation
5.2. Closing of cases inside Credit 360 Reporting tool
Evidence that all cases are closed within 7 days after the case was reported inside the Credit 360
Reporting Tool. Exceptions only acceptable if reason of delay is documented.
5,3, Corrective/preventative measures tracked to completion.
Evidence that defined corrective/preventative measures are tracked to completion.
5.4. Safety Pyramid
Targets for ideal safety pyramid are set.
5.5. Execution check
Employees can explain the basic aspects of the latest TRI / SIF that happened in the department and
the latest safety alerts that were communicated in the department
5..6. APP available for reporting of hazards / unsafe conditions / unsafe behaviors
2. Injury Management
Checkpoint level 1
1.1. SOP
RACI describing the Roles and Responsibilities with regards to the Legal Compliance Program
available, including who is responsible for safety regulatory compliance with regards to change
management.
2.2. Safety register available that contains summary of applicable safety & occupational health
requirements with focus on operational controls.
Checkpoint Level 3 :
3.1. All Safety & Occupational Health permits, licenses, authorizations, registrations and similar
documents entered into Credit 360 Permits & Licenses Module
3.2. All Safety & Occupational Health requirements assessed via a structured methodology.
3.3. Applicability determination completed (and documented) by qualified individual.
3.4. Safety register denotes whom in the organization is responsible for compliance with each
applicable safety & occupational health requirements.
Checkpoint Level 4:
4.1. Change management
System in place to identify and track new, proposed & emerging legislation, regulations and
requirements
4.2. Change management
Applicability determination re-validated and safety register updated as changes occur or reviewed at
least once per year.
4.3. Credit 360 Permits & Licenses module: all applicable fields completed and updated after a
change (must demonstrate not just list on Credit 360 screen)
Checkpoint Level 5:
5.1. Safety permits or licenses that are in progress with agreement of authorities and not
completed are included in plant action log.
5.2. Submittals to authorities
Safety regulatory submittals made to external agencies via certified mail or similar commercial
delivery service
5.3.. Plant action log for in progress with agreement of authorities and not completed permits
are part of MCRS (must show evidence)
5.4. Evidence that the safety register validated by General/Plant Manager on annual basis
2. Safety Regulatory Compliance Management execution
Checkpoint Level 1:
1.1. Execution Check
Main legal compliance gaps found during audit that have not been identified by the facility
Checkpoint Level 2
2.1. .Evidence that Safety & Occupational Health requirements are embedded into routine such as
SOPs, maintenance routines (SAP), monitoring inspections, OPLs, etc.
2.2. Training
All Managers and supervisors have been trained on the Safety and Occupation Health Regulatory
Requirements that are applicable in their department. Training records available.
Checkpoint Level 3
3.1. Evidence that the ES manager has communicated the findings of the Safety Compliance check
(see VPO.SAFE.3.2.04.Safety Monitoring) to the Plant Manager and Departmental Managers
Checkpoint Level 4
4.1. All managers can speak to the regulatory requirements within their departments and
demonstrate the safety and occupational health register
Checkpoint Level 5
5.1. Plant action log for identified improvement opportunities with regards to legal compliance is part
of MCRS of the plant.
Checkpoint level 2
2.2. Management of Change CAPEX projects
Evidence of alignment meetings between ES Manager (or delegate) and the Project Team before
start-up of the project.
2.2. Tasks managed by T.S. and other Departments
Evidence that relevant contractor safety related information exchange happens during joint daily
planning meeting (focus on ongoing projects and projects due to start)
2.3. Temporary Equipment - Permits and Licenses
Evidence that temporary legally required permits or licenses (Environmental Safety) are present
before start of the works no works can start if not all legally required permits are present.
2.4. Temporary Equipment - approval
For the equipment that is brought on site by the contractor / service provider, the Project Manager
or designated ABI Manager checks upfront if necessary certificates are present (no limited list):
o All lifting equipment (see VPO.SAFE.3.1.03.Lifting Equipment) including cranes
o All working on height equipment (see VPO.SAFE.3.1.02. Working at Heights) including installed
lifelines, mobile platforms, scaffolding, safety harnesses etc
o All pressure vessels, including gas cylinders
o Temporary electrical cupboards
2.4 .Monthly evaluation
A monthly audit of the contractor safety management process is done by ES manager (as prescribed
in VPO.SAFE.3.1.13. Contractor Management )
Results of this contractor evaluation are communicated to Plant Manager, to Procurement, to ZBS ES
and ZBS Projects Department for consideration of future projects (give examples as evidence)
Checkpoint level 3
3.1. MCRS
Evidence that the ES Manager (or delegate see RACI) participates at the plant monthly MCRS
Capex-project meeting to exchange safety related information and to evaluate BOPS projects
3.2. MCRS
Evidence that the ES Manager organizes a monthly Capex -project meeting to exchange safety
related information & to evaluate Logistics projects with Logistics Manager
3.3. MCRS
Evidence of a weekly information exchange / review by ES manager (or delegate see RACI) and
T.S. / other departments about contractor works and service provider work (for work not part of their
long-term safety plan) / that are ordered / managed by them.
3.4. Legal
Has the applicable local legislation been identified and interpreted by the ES department?
Checkpoint level 4
4.1.Management of Change CAPEX projects
Evidence that ES Manager ( or delegate see RACI) is involved in design phase for relevant*
Logistics and BOPS Capex projects with Management of Change process completed and validated
by ES Manager and applicable requirements inserted in the Project Statement by Projects team.
(*involving critical tasks as defined in VPO.SAFE.3.1.13. Contractor and Service Provider Safety
Management + works with risk for exposures to asbestos and works involving radio-active sources)
4.2. Management of Change Contractor works other than CAPEX project
Evidence that ES Manager (or delegate see RACI) is involved before bidding phase for relevant*
contractor works.
(*involving critical tasks as defined in VPO.SAFE.3.1.13. Contractor and Service Provider Safety
Management + works with risk for exposures to asbestos and works involving radio-active sources)
Checkpoint level 5
5.1. Service provider contracts
Evidence that ES Manager (or delegate see RACI) is involved before bidding phase in all service
provider contracts.
2. Risk Assessment (safety plan / method statements)
Pre-requisite
If there is any evidence that contractor roof works / works on ammonia / works on boilers and
pressurized equipment / works on High Voltage have been done or are going on without validated
Safety plan / method statement / work permit between previous audit and current audit, the score
for the whole block must be ZERO for all departments.
Checkpoint level 1
1.1. Defining the level of appropriate level of risk assessment at tender phase
Evidence that Project Manager or designated ABI Manager has defined the appropriate level of risk
assessment and safety documentation in the tender.
1.2.Safety Plan for Projects (CAPEX, Growth, VE) managed by ZBS, Zone Logistics, ZTD
Project Manager or designated ABI Manager ensures that appropriate level of risk assessment and
safety documentation is available before the works start.
When multiple (sub-)contractors are involved or multiple Critical activities with high risk are needed,
always a formal safety plan is made (see VPO.SAFE.3.1.13. Contractor Management).
1.3.Safety Plan for Projects (CAPEX, Growth, VE) managed by Facility
Project Manager or designated ABI Manager ensures that appropriate level of risk assessment and
safety documentation is available before the works start.
When multiple (sub-)contractors are involved or multiple Critical activities with high risk are needed,
always a formal safety plan is made (see VPO.SAFE.3.1.13. Contractor Management).
1.4.Safety Plan for service providers and in house contractors
For service providers and in house contractors (and their subcontractors), a Long term Safety plan is
available with risk assessment and method statement of all recurrent routine activities
Checkpoint level 2
2.1. Risk Assessment / Method Statement
For projects with Safety Plan, formal risk assessments/ method statements are delivered for each
activity and task that is performed inside the duration and scope of the Safety Plan by each
contractor, service provider and in house contractor - with formal evidence
2.2. Risk Assessment / Method Statement
For all contractor works and tasks outside the scope of larger projects (e.g. managed by the facility)
and for all projects without formal Safety Plan, formal risk assessments/ method statements must be
delivered by each contractor, service provider and in house contractor before start of each works with formal evidence
2.3. Risk Assessment / Method Statement
For service provider and in house contractors, formal risk assessments/ method statements are
delivered for each activity and task that is performed outside the duration and scope of the Long
Term Safety Plan - with formal evidence.
2.4. Risk Assessment / Method Statement
The final risk assessments / method statements provided by the contractor are always preceded by
and the result of a pre-visit on site at the area where the contractor works will take place.
Checkpoint level 3
3.1. Validation of Safety plans / Risk Assessments / Method statements
Evidence that all safety plans / risk assessments /method statements are validated by responsible
project manager or designated ABI Manager.
3.2. Validation of Safety plans / Risk Assessments / Method statements
Evidence that the ES department has been consulted during validation process of the Safety plans /
Risk Assessments / Method statements
of contractor checks during daily / weekly / monthly supervisors and managers safety
1.2. Supervision
Evidence that each contractor (including subcontractor) has formally appointed a contractor site
safety supervisor, who is considered as Single Point of contact (SPOC) for the facility for all safety
related items
1.3. Supervision
Evidence that a designated full time safety supervisor is appointed for large projects and projects
with high safety risks.
1.4. Supervision
Evidence that permanent (= continuously) safety supervision is organized by the contractor for
critical tasks (see VPO.SAFE.3.1.13. Contractor and Service Provider Safety Management).
Supervision must not combined with other tasks other than supervise.
1.5. Supervision
Evidence that, if correct level of safety supervision is not implemented, the works are
stopped/postponed/ cancelled until supervision is in place.
Checkpoint level 2
2.1. Last Check
Evidence that, for the start of all contractor works involving critical tasks, a last check is performed
by Project manager or designated ABI Manager in presence of a) the responsible of the department
where the works take place and b) the contractor site safety supervisor
Checkpoint level 3
3.1. Legal requirements for supervision
Evidence that the level of safety supervision is complying with the local legislative requirements
3.2. Supervision
Evidence that there is a process in place to check compliance with safety requirements (on top of
critical tasks) see Long Term Safety Plan - by service providers (in-house contractors
Checkpoint level 4
4.1. Green field & Big extension projects
Evidence that, For Green field or big extension projects, safety management structure is fully
compliant with the Global requirements ( see Annex VPO.SAFE.3.1.13.7)
4.2. Works outside normal working hours
Evidence that there is a process in place to ensure the correct level of supervision in periods of low
production or of limited presence of facility personnel (weekends, holiday, facility shut downs,...)
Checkpoint level 5
5.1. Works outside normal working hours
Evidence that contractor works in periods of low production can only take place after formal approval
of ES Manager or a delegate ( Departmental Manager, facility Manager, TS Manager...)
5.2. Last Check
Evidence that, for the start of all contractor works, a last check is performed by Project manager or
designated ABI Manager in presence of a) the responsible of the department where the works take
place and b) the contractor site safety supervisor
4. Training and Communication
Note: for contactor and service provider safety induction: see VPO.SAFE.3.1.14. Safety Induction,
Training and Coaching
Checkpoint level 1
1,1, Training
All managers and supervisors must be trained in the contractor management process. Trainings are
recorded.
Checkpoint level 2
2.1. Toolbox meetings for contractors
Evidence that regular toolbox meetings are organized by the contractor. Frequency depending on
the risks involved: minimum 3 times a week / daily for large projects, for projects with multiple
(sub-)contractors working in the same area at the same time / daily for contractor works involving
Critical tasks / immediately after each safety incident that has taken place.
The outcome (action plan / TOR) of each toolbox meeting is formalized and filed by designated ABImanager or Project Manager
Checkpoint level 3
3.1. Toolbox meetings for service providers
Evidence that regular toolbox meetings are organized by the service provider (in-house contractor).
Frequency depending on the risks involved: minimum 1 time a week / daily for works involving
Critical tasks / immediately after each safety incident that has taken place.
The outcome (action plan / TOR) of each toolbox meeting is formalized and filed by designated ABImanager or Project Manager
Checkpoint level 4
4.1. Safety alerts
Evidence that relevant safety alerts are reviewed with the contractors / service providers
5.1. Visual Boards
Visual board in place for contractor works (for Green field and big extension projects) and for
permanent service providers (in house contractors).
5. Contractor Selection and Evalution
Pre-requisite
If there is any evidence that roof works are or have been assigned between previous audit and
current audit to companies that are not certified for roof works / works on ammonia / works on
boilers and pressurized equipment / works on High Voltage , the score for the whole block must be
ZERO for all departments
Checkpoint level 1
1.1. Review Safety Performance
Evidence that safety performance of contractors is reviewed after each project
1.2. Review Safety Performance
Evidence that safety performance of service providers (including in-house contractors) is reviewed
at least 4 times per year
Checkpoint level 2
2.1. Verification of Employee skills
Evidence that, for tasks that require specific skills or medical conditions to do the job safely, the
contractor / service provider has provided the written evidence to show that the employees have
been properly trained and have been certified for the job (see also list in chapter 5.1. of
VPO.SAFE.3.1.13. Contractor and Service Provider Safety Management)
Checkpoint level 3
3.1. Prequalification
Evidence of prequalification of contractors and service providers before contracts are signed.
Prequalification process must contain following mandatory elements:.
a. The contractor / service provider company written safety program
b. The safety support structure of the contractor / service provider company
c. The contractor company safety performance / service provider for the previous 3 year period
Checkpoint level 4
1.2. Contractor and Service Providers, Trade and AB-InBev Visitors Registration
Is there a sign in and out process when entering and exiting the facility (badge or register)?
1.3. RACI
RACI describing the Roles and Responsibilities with regards to Induction and Registration available.
Checkpoints Level 2
2.1. Execution check
No Contractor and Service Providers, Trade and AB-InBev Visitors found that are not registered
2.2. Contractor and Service Providers, Trade and AB-InBev Visitors Initial Induction
Annual initial safety induction completed with all required content?
Register (written or electronic) tracking when latest induction was completed?
Leaflet with content of safety induction provided to Contractors, Service Providers, AB-InBev Visitors
and Trade Visitors
2.3. Contractor and Service Providers, Trade and AB-InBev Visitors Registration and Induction
Departmental on the job specific
Includes layout of the department, specific departmental hazards, safety rules and
emergency/evacuation procedures, MOC, PPE, work permits, + safety plan/method statement and
supervision (contractors/service providers only)
Checkpoints Level 3
3.1. Legal
Has the applicable local legislation been identified and interpreted by the ES department?
3.2. Contractor and Service Providers, Trade and AB-InBev Visitors Initial Induction - test
Test conducted to ensure good understanding? Additional training for anyone who fails training?
3.3. Execution check
No Contractor and Service Providers, Trade and AB-InBev Visitors found that have not gone through
the induction process
3.4. Execution Check
Can Contractor and Service Providers, Trade and AB-InBev Visitors explain induction process?
3.5. Tourist Visitor Registration and Safety Induction Guide training
Tour guides trained on required topics? (tourist visitor induction program, plant evacuation
procedures, first aid procedures of the plant, major hazards that tourists can be exposed to and how
to deal with it).
Coaching
(including
temporary
workers,
Checkpoints Level 1
1.1. Employee Registration
Is there a sign in and out process for employees when entering and exiting the facility (badge or
register)?
1.2. Risk Assessment, SOP & OPL
Overall SOP describing the employee safety induction, training and coaching program available?
SOP must comply with VPO procedure.
1.3. RACI
RACI describing the Roles and Responsibilities with regards to Employee Induction, Training and
Coaching available?
Checkpoints Level 2
2.1. New Hires/ Induction completed before starting to perform their job
Includes minimum content? (AB-InBev Safety Policy, sign in/out and security procedure, plant lay
out, specific plant hazards, work permits system, general safety rules, emergency and evacuation
procedures, Occupational Injury & Diseases Reporting, Investigation, Communication &
Management, Safety Plan/Method statement/supervision requirements (for contractors and service
providers), legal training requirements, SIF and unsafe behavior prevention, safety organization,
department and job specific hazards, risk assessments, SIO/SHO, Occ. Health, Safety
Communications.)
Records available?
2.2. Change of Function/ Induction completed before starting to perform their job
Includes minimum content? (SIF and unsafe behavior prevention, safety organization, department
and job specific hazards, risk assessments, SIO/SHO, Occ. Health, Safety Communications.)
Records available?
Checkpoints Level 3:
3.1. Legal
Has the applicable legislation been identified and interpreted by the ES department?
3.2. Training and coaching plan
Evidence that the annual Safety Training and Safety Coaching needs are defined annually
Part of Management review?
3.3. Safety training and coaching plan inputs
Is the plan defined by the required inputs? (Results of the safety questions engagement survey,
results of safety culture assessments, behavioral safety observations, safety aspects of the
department and plant, existing training and coaching plan, legislative requirements, training gaps
arising out of injury/incidents/hazard investigations, audit and inspection findings (internal/external),
employee/manager concerns.
3.4. Specific immediate training needs
Driven by changes of equipment, materials, procedures, injury/incidents/hazard investigations,
workplace inspections, audits?
1. Emergency Response
Checkpoint level 1
1.1. SOP
Overall SOP describing the emergency program : Communication internal and external /. Evacuation
(own employees, visitors, contractors, neighbors) - including safeguarding of values / Combat and
must include: After care, first aid, evacuation, training and information and testing and review.
Checkpoint level 2
2.1. RACI
RACI describing the Roles and Responsibilities in case of an emergency is available.
2.2. First Aid
The facility has set up a First Aid system in order to support the injury management and to deal with
casualties, whatever the cause. The First Aid support is organized as such that proper First Aid can
be provided timely, at all times, at the whole plant area. The First aid system is validated by the
Company Medical Specialists and the Safety Committee.
2.3. Hazmat
Risk assessment is done to identify the need for a HAZMAT Emergency Response Team (Such a
team is always obliged if required by local law).
Checkpoint level 3
3.1. Scope
Emergency program cover situations that can be treated with the own plant resources; emergency
situations for which the brewery has to call in external assistance; crisis situations, including the
collaboration with the country, zone and corporate crisis teams.
3.2. Scope
Emergency program covers periods of low and / or non-activity such as nights, weekends, holidays,
etc.
3.3. Scope
Emergency program covers emergency risks that have been identified by the safety (and
environmental) analysis.
3.4. Legal - Has the applicable local legislation been identified and interpreted by the ES
department?
3.5. Training
Employees properly trained in order to deal effectively with emergency situations. Trainings records
available.
3.6. Training
Evidence of at least 1 full evacuation exercise per year in the facility.
3.7. Training
Evidence of training of First Aiders, including the use of AED. Employees properly trained in order to
deal effectively with emergency situations. Trainings records available.
3.8. Training
Evidence of training of the HAZMAT Team (in case a HAZMAT team is needed by risk assessment or
law). Trainings records available.
3.9. Testing evacuation alarms
Evacuation alarm is tested according to legal requirements or at least quarterly
Checkpoint level 4
4.1. Alignment
The emergency procedures aligned with: The AB-InBev crisis management procedures; Quality crisis
procedures (e.g. recalls, contamination of a well); Local city, province or country crisis procedures,
Local emergency services (inform, consult and co-operate, Adjacent residents and companies,
People crisis procedures and Security procedures.
4.2. Communication
All occurred emergency situations communicated to the ZBS ES manager. A crisis must additionally
be communicated to country crisis management team coordinator.
4.3.. AED
Facility has at least 1 fully functional AED, located at a central location at the plant that is easily
accessible at all time. The AED and batteries are tested, inspected and maintained according to
manufacturers specifications.
4.4. Execution check
Employees can explain how to act in case of an emergency + location of the assembly points /
location of the nearest emergency shower and eye wash stations / location of the nearest First Aid /
location of the nearest fire-fighting equipment.
4.5. Training
Evidence of at least 1 yearly exercise involving an ammonia emergency (for plants with ammonia
containing cooling installations)
4.6. Training
Evidence of at least 1 yearly exercise involving the HAZMAT team(for plants with HAZMAT team)
4.7. Evaluation and action plans
Evidence of evaluation of all emergency exercises and occurred emergency situations with action
plan to close the identified gaps
Checkpoint level 5
5.1 Review
ES manager assures at least yearly a thorough check of all emergency equipment and an overall
review of the emergency procedures
5.2 AED
Plant made risk assessment to define additional needs for AED
5.3. Maintenance / inspection
Inspection of emergency response equipment and AED managed via a preventive maintenance work
order system (SAP or other)
5.2. Communication
Communication of hazards is done via a visual board at the entrance of the department
2. Safety Risk Assessments Job Hazard Analysis
Checkpoint level 1
1.1. 3 year plan
3 year plan (with detailed milestones) available to ensure that all the jobs of the department are
subject to an in-depth Job Hazard Analysis.
1.2. 3 year plan - priorities
Milestones of 3 year plan take the priority setting of VPO.SAFE.3.2.02. Safety Risk Assessments into
account/ Jobs which caused TRI , SIF, FAI, incidents / jobs with high potential to cause SIF or injuries,
even if there is no history of such problems / Jobs in which one simple human mistake could lead to
SIF / Jobs that are new to your operation or have been changed / Jobs with high turn over, use of
temporary workers, students
Checkpoint level 2
2.1. Job Hazard Analysis Process
Job Hazard analysis process
Assessments
Safety Risk
Checkpoint level 3
3.1. Job Hazard Analysis for Lone Workers
Job Hazard Analysis has been done for all Lone workers
3.2. Job Hazard Analysis disabled employees and for workers with medical condition
Job Hazard Analysis has been done for all jobs done by disabled employees and for workers with
medical condition
Checkpoint level 4
4.1. Job Hazard Analysis completed
Job Hazard Analysis completed according 3 year plan
4.2. Review
Evidence that the Job Hazard ANALYSIS are reviewed yearly and if relevant changes occur.
4.3. Link with SOP / training
Evidence of clear link between departmental SOP / training and Job Hazard Analysis
Checkpoint level 5
safety
is
based
upon
the
risk
assessment.
See
Checkpoint level 2
2.1. MSDS
MSDS of all hazardous substances used by the facility available at the facility.
2.2. MSDS
Where hazardous substances are used / present, the basic safety information based on the MSDS is
locally available (See VPO.SAFE.3.1.8.Hazardous substances).
Checkpoint level 3
3.1. Training
Employees trained about signalization. Training records available.
3.2. Legal
Has the applicable local legislation been identified and interpreted by the ES department?
3.3. Induction
Emergency and other relevant signalization part of induction of contractors and visitors
3.4. MSDS
MSDS of all hazardous substances used by the contractors and service providers available at the
facility.
Checkpoint level 4
4.1. Execution check
Employees can explain the safety signalization.
4.2. Execution check
Radio, MP3 head phones etc. not used in production areas.
Minimum:
Also applicable for CIP vessels and other equipment containing hazardous substances (e.g. bottle
washers).
The maximum volume must be indicated on bunds (containments).
4.7. Execution Check
Handrails on stairs, platforms, etc must be Yellow.
If stainless steel is used: only the first and last 15 cm of the hand rail. Alternative is to put signs
hold the handrail.
Lifting beams etc. must be Yellow.
4.8. Execution Check
Automatic (motorized) horizontal moving gates are equipped with and audible (horn) and visible
(flash light) alarm when closing and opening.
4.9. Execution Check
Control buttons, switches, indicator lamps and other means of control are properly labeled with
pictograms or text in the language of the country.
4.10.Execution check
Proper identification of all piping
Checkpoint level 5
Talk
Checkpoint level 2
2.1. Plant Manager weekly
Evidence of effective Plant Manager weekly safety monitoring
2.2. Departmental Manager weekly
Evidence of effective Departmental Manager weekly safety monitoring
2.3. Supervisor & Process Engineer weekly safety monitoring
Evidence of effective t Supervisor & Process Engineer weekly Safety monitoring
2.4. ES Manager
Evidence that ES Manager is participating and supporting the Departmental Manager weekly safety
monitoring
Checkpoint level 3
3.1. Plant Manager Daily
Evidence of effective Plant Manager daily safety monitoring
3.2. Departmental Manager daily
Evidence of effective Departmental Manager daily safety monitoring
3.3. Supervisor & Process Engineer daily safety monitoring
Evidence of effective Supervisor & Process Engineer daily safety monitoring
3.4. ES Manager
Evidence of effective ES Manager daily safety monitoring (mandatory SIF check) and evidence that
ES Manager is participating and supporting the Departmental Manager daily safety monitoring
Checkpoint level 4
4.1. Safety Champions
Evidence that Safety Champions are participating and supporting the daily / weekly / monthly safety
routines in the department
4.2. Monitoring of safety during overhauls.
Evidence of effective daily safety monitoring during overhauls
Checkpoint level 5
5.1. Execution check
Evidence of positive recognition of safe behavior (interview employees)
5.2. Daily 5 minutes safety meeting
Effective 5 minute daily safety meeting by Plant Manager
5.3. CCTV use
Evidence of a process for use of CCTV for pro-active safety monitoring (unless forbidden by law)
2. Improve Workplace conditions by Safety Monitoring
Checkpoint level 1
1.1. Weekly safety-critical equipment checks - inventory
List of safety-critical equipment is available.
1.2. Periodic safety equipment not part of critical inventory
List of safety equipment (not part of the safety-critical equipment list) is available. Frequency of
checks is indicated
1.3. Responsibilities - RACI
RACI describing the Roles and Responsibilities for safety monitoring available?
Checkpoint level 2
2.1. Weekly safety critical equipment check inventory mandatory items
The Mandatory items as described in VPO.SAFE.3.2.04.Safety Monitoring and Auditing are part of the
inventory for process area / packaging / utilities / maintenance / logistics / environmental / quality
2.2. Weekly safety equipment check inventory mandatory items
The Mandatory items( not part of the safety-critical equipment check) as described in
VPO.SAFE.3.2.04.Safety Monitoring and Auditing are part of the inventory (Fire and explosion
detection equipment (smoke detectors) / Emergency alarm systems (alarm, evacuation, horns) /
Firefighting equipment (sprinkles and water pumps, fire hydrants, fire extinguishers) /Facilities to
reduce the spreading of fires (fire walls, fire doors,) / Facilities to remove smoke in case of fire /
Collective protective fall arrest equipment (lifelines,) / Collective protective equipment to reduce
impact of chemical exposure (emergency showers, eye wash stations,) / PPE availability at
departments (ear plug dispensers etc) / First Aid equipment / Defibrillator and other medical
equipment / Ventilation hoods / Safety signalization / CCTV for safety purposes
2.3. Execution check
No defective safety-critical equipment found during audit
Checkpoint level 3
3.1. Execution check
No defective safety equipment (not part of critical-safety equipment check) a
Checkpoint level 4
4.1. Schemes of safety critical equipment
Scheme is available that identifies the items to check on equipment(safety switches, guarding,
emergency stops, safety signs, etc.)
Checkpoint level 5
5.1. SOP for alternative system
General SOP available that describes the alternative systems that must be put in place if safetycritical equipment is out of order.
5.2. Validation by supervisor
Weekly critical equipment checks are formally validated by supervisor
5.3. Inspection
Checks via a preventive maintenance work order system ( SAP or other)?
3. Safety Compliance Check
Checkpoint level 1
1.1. Safety compliance check plan
Yearly safety compliance check plan available.
Checkpoint level 2
2.1. Safety compliance check plan
Yearly safety compliance check plan identifies the critical requirements
Checkpoint level 3
3.1. Execution check
Yearly safety compliance check executed according to plan
Checkpoint level 4
4.1. Reporting
Yearly safety compliance check reported to Plant Manager, the concerned Departmental Managers
and the ZBS ES Manager.
Checkpoint level 5
5.1. Action plan
Yearly safety compliance check part of Management review and action plans
4. Property Loss Control inspections (GRC)
Checkpoint level 1
1.1. Process: Review of initial report
Evidence that Plant Manager and ES Manager have reviewed the initial report and have given
feedback to the audit company and the Global Risk Management & Insurance Department within 1
month after receiving the initial report.
Score Not Applicable if plant is not audited by GRC
1.2. Process: Feedback on Final report
Feedback on Final report by Plant Manager and ES Manager within 30 days after receiving the final
report to the to the audit company.
Score Not Applicable if plant is not audited by GRC
Checkpoint level 2
2.1. Audit result Human elements
No Red blocks (inadequate) on the Human Element Assessment.
Score Not Applicable if plant is not audited by GRC
Checkpoint level 3
3.1. Action plan
Formal action plan to get the facility to typical risk (overall score > 60).
Score Not Applicable if plant is not audited by GRC
3.2. Action plan CAPEX related
For CAPEX related items: Proof that CAPEX has been allocated or has been requested but not been
approved by Zone or Global.
Score Not Applicable if plant is not audited by GRC
Checkpoint level 4
Evidence of specific trainings for Safety Champions such as train the trainer / safety
observations / ... Trainings are recorded
Checkpoint level 5
5.1. Execution check
Employees of the department positively comment performance and impact of Safety Champion
5. Safe behaviors
Key Safe Behavior for Leadership, pre-requisite
Leadership (Managers and Supervisors /FLM) comply at all times with
PPE requirements
Hold the handrails using stairs
Using Mobil Phone according to requirements
Respect the walkways
Always score ZERO if more than 1 Manager / Supervisor is not complying during audit
Checkpoint level 1
1.1. Defined
SIF (Serious Injury or Fatality) Prevention Behaviors, the Focus Safe Behaviors and the Key Safe
Behaviors for Leadership defined for each department.
Checkpoint level 2
2.1. Criteria
SIF Prevention Behaviors comply with the VPO criteria (non-compliance can cause SIF / no room for
interpretation / easy to understand / applicable for everybody).
Focus Safe Behaviors comply with the VPO criteria (avoiding TRI / based on analysis of results and
observations / success factors defined).
Key Safe Behaviors for Leadership comply with the VPO criteria (effectively contributing to
establishing positive safety culture in facility).
2.2. Consequences SIF Prevention Behaviors
Disciplinary consequences for unsafe behaviors / non-compliance with SIF Prevention Behaviors
clearly defined and communicated to the employees.
2.3. SIF Prevention Behaviors for Contractors and Service Providers
SIF Prevention Behaviors for Contractors and Service Provides defined and
induction.
Checkpoint level 3
3.1. Behavioral safety KPI
Behavioral safety KPI tracked and follow up(Global Safety Engagement Survey / # Behavioral Safety
Observations# Behavioral Safety observations per FTE / # Safety Champions / # Trained Observers
per ( # (Managers + Safety Champions)
3.2. Communication
Communication of SIF Prevention Behaviors, Focus Safe Behaviors and Key Safe Behavior for
Leadership in the facility (visual boards, safety routines, meetings and other).
3.3. Training
Management and Supervisors trained in safety coaching techniques (focus on positive reenforcement) and the Human Behavior Mechanism (ABC model). Trainings recorded.
3.4.. Training
Management, Supervisors, Safety Champions and all employee doing Operational Work Diagnosis
(OWD) is trained in Behavioral Safety Observations techniques. Trainings are recorded.
3.5. Training
Safety manager is trained in train the trainer. Trainings are recorded.
3.6. Use of mobile phones and suchlike devices
Employees comply with the requirement of VPO.SAFE.3.2.06.04 regarding Use of mobile phones and
suchlike devices (stopped activities / 2 w away from equipment, vehicle, / never while driving /
never while using stairs/ never in areas with potential explosive area)
3.7. Disciplinary process
Disciplinary process known and understood by employees
Checkpoint level 4
4.1. Disciplinary process implementation
Evidence of implementation of disciplinary process
4.2. Execution Check SIF Prevention Behaviors
SIF Prevention Behaviors and the consequences for not complying known, understood and
implemented by the employees, contractors and service providers?
4.3. Execution Check Focus Safe Behaviors
Focus Safe Behaviors understood and implemented by the employees,
providers?
4.4. Execution Check Key Safe Behavior for Leadership
Key Safe Behavior for Leadership understood and implemented by the managers and supervisors
4.5. Update SIF Prevention Behaviors
SIF Prevention Behaviors reviewed yearly.
Key Safe Behavior for Leadership reviewed yearly.
Focus Safe Behaviors updated if success factors are achieved
4.6. Execution check
Supervisors and managers can give concrete examples of postive re-enforcement of safe behaviors
Checkpoint level 5
5.1.. Use of technology
Use of CCTV recording as training material for Behavioral Safety Observation Training and Coaching.
(Score NOT APPLICABLE if not allowed by law)
5.2. Coaching by ES department
Evidence of coaching of by ES Department of the Management, Supervisors and Safety Champions
on risk awareness.
5.3. Behavioral safety awareness test new hires
Safety awareness check by means of a formal test part of the hiring process.
5.4. Daily 5 minutes safety meeting
Effective 5 minute daily safety meeting by Plant Manager
5.4. Leadership key safe behavior and coaching / OPR
Evidence that review of implementation of the leadership key safe behavior is part of the coaching
process between manager and employee and the OPR process.
All programs in place to help protect employees from the workplace hazards which can cause short
or long term work related illnesses, as established by the Occupational Health Hazard Risk
Assessment (such as Respiratory Protection / Hearing Conservation / Asbestos Management / Lead
Hazard Control / Mold and Fungi Hazard Control / Methylene Chloride / Blood Borne Pathogens /
Phosphine Air Monitoring)
5.2. Execution check
Employees explain the potential occupational illnesses linked to their job and the preventive
measures put in place.
2. Ergonomics Lifting / Manual handling
Checkpoint level 1
1.1. Risk Assessment
Risk assessment on manual handling available to identify the appropriate measures on technical,
organizational and behavioral level.
Checkpoint level 2
2.1. Maximum weights
Maximum weight that can be handled by 1 person defined and communicated to employees.
Checkpoint level 3
3.1. Lifting aids
Lifting aids available and used See VPO.SAFE.3.2.07.16. Ergonomics Lifting, Manual Handling.
Checkpoint level 4
4.1. Organizational measures
Organizational measures implemented ( limit the frequency of manual handling activities / divide the
weight of the load / safe environment) - part of SOP
Checkpoint level 5
4.2. Work station design
Work stations designed in accordance with
Handling.
4.3. Programs
Manual handling / lifting techniques trained to all employees that are exposed. Trainings recorded
Checkpoint level 5
5.1. Execution check
Employees explain manual handling hazars linked to their job and the preventive measures put in
place.
3. Ergonomics - Repetitive Motion Illness
Checkpoint level 1
1.1. Risk assessment
Risk assessment done for every job where more than 1 employee have been diagnosed with a
repetitive Motion Illness and the trigger conditions have been met.
(Score Not Applicable for this whole question if criteria above are not met)
Checkpoint level 3
3.1. Control measures defined
When Trigger Conditions are met: facility implemented a process designed to minimize
musculoskeletal injuries (work site evaluation, control of exposures thought to have contributed to
illness / injury and training of employees)
Checkpoint level 5
5.1. Training
Trainings for employees in identical work activity that has exceeded the program trigger.
Checkpoint level 2
2.1. Safety Policy
Employees can indicate where the safety policy is posted
Checkpoint level 3
3.1. Onboarding and induction training
Safety Policy included in onboarding and contractor / service provider induction
Checkpoint level 4
4.1. Safety Charter
Evidence that Plant Manager and Departmental Managers have reviewed the Safety Charter with her
/ his direct reports.
4.2. Exceution check Safety Policy
Employees are familiar with Safety Policy, can explain how they implement the basics of the policy in
their daily job.
Checkpoint level 5
5.1. Evidence that Safety Charter has been reviewed with all employees
2. Safety Committee
Checkpoint level 1
1.1. Safety Committee
Safety Committee established in the plant, according to legal requirements or requirements of VPO
Checkpoint level 2
2.1. Responsibilities - RACI
RACI describing the Roles and Responsibilities of the Safety Committee available
Checkpoint level 3
3.1. Action Plan
Action plan of each safety committee available
Checkpoint level 4
Minutes of meetings of safety commitee avaialble for the employees
Checkpoint level 5
5.1. Execution check - Safety Committee
Employees can clarify roles and responsibilities of the Safety Committee and know who are the
members representing them.
3. Safety Promotion
Checkpoint level 1
1.1. Responsibilities - RACI
RACI describing the Roles and Responsibilities for Safety Promotion (Safety First / Safety Days / World
Safety Day / Safety at Home / Safe Driving, TSR)
Checkpoint level 2
2.1. Safety First
Evidence that Safety First ! Campaign of the zones are implemented at the facility.
Checkpoint level 3
3.1. Safety Day
Evidence of Safety Day organization in the facility (can be replaced by a similar process (example
safety week) after agreement of Zone and Global Safety Department)
3.2. World Safety Day
Evidence of active participating on World Safety Day.
Checkpoint level 4
4.1. Together For Safer Roads (TSR)
Evidence of TSR initiatives
Checkpoint level 5
5.1 Execution Check
Employees can explain Safety First! Actions / Safety Days / World Safety Day / TSR
5.2. Review
Evaluation of the safety promotion activities available for improvement of future activities
including action plan
5.3. Execution Check
Action log for the actions coming from the Safety First!, World Safety Day , Safety Day and TSR
initiatives