Workplace Safety Audit Checklist (Free, Export)

0%

0 of 30 items complete

7 critical items still open - these are the highest-risk gaps.

Download checklist:

Housekeeping and walking surfaces

Aisles and exits are marked, clear and unobstructedCRITICALFloors are dry, free of oil, chips and trip hazardsStairs and platforms have handrails and guardrails in good conditionMaterial storage is stable and within rack load ratingsLighting is adequate in work areas and walkwaysWaste and scrap containers are labeled and not overfilled

Machine guarding and energy control

Point of operation and moving parts are guarded on all machinesCRITICALGuards and interlocks are in place and not bypassedCRITICALMachine-specific lockout tagout procedures exist and are postedCRITICALAnnual periodic inspection of LOTO procedures is documentedEmergency stops are accessible and testedAuthorized employees have current LOTO training records

Electrical and fire protection

Electrical panels have 36 inch clear access and covers in placeCRITICALNo damaged cords, extension cords used as permanent wiring or daisy chainsFire extinguishers are charged, inspected monthly and accessibleHot work permits are used and fire watch is assignedFlammable liquids are in approved cabinets or containersSprinklers have 18 inch clearance below the heads

Chemicals, PPE and health

Safety data sheets are available for every hazardous chemicalCRITICALContainers are labeled in line with the hazard communication standardWritten PPE hazard assessment is current and certifiedEye wash and shower stations are accessible and flushed weeklyHearing protection and noise monitoring are in place where requiredRespirator program, fit tests and medical evaluations are current

Emergency readiness and programs

Emergency action plan is current, with evacuation routes postedCRITICALEvacuation drills are held and recorded at least annuallyFirst aid kits are stocked and trained responders are on every shiftPowered industrial truck operators are trained and evaluatedOSHA 300 log and 300A summary are complete and posted when requiredIncident investigations and corrective actions are closed on time

Each checked item counts toward the score. Any unchecked critical item should be treated as an immediate corrective action regardless of the overall score. This checklist is a general guide and not a substitute for the OSHA standards and local regulations that apply to your site.

Turn audit findings into work orders

An optional review of routing safety findings to maintenance and tracking them to closure.

Optional. The tool and every export work without this. No spam.

How to use this checklist

Walk the area with a supervisor or worker representative and verify each item by observation and by checking records, not by asking. Tick the items that pass, leave the failures unticked and note the location and the action in your export. Items marked critical relate to hazards that can cause severe injury quickly, such as missing guards, no energy control or blocked exits. Run the checklist monthly for each area, rotate who leads it, and compare results over time to see whether the same weaknesses recur.

What the groups cover

The five groups follow common OSHA focus areas. Walking and working surfaces, machine guarding, lockout tagout, hazard communication, powered industrial trucks, respiratory protection and electrical safety appear regularly on lists of frequently cited standards. Emergency action planning and fire protection round out the audit. Adapt the items to your site: a foundry, a defense electronics assembly line and a fiber optic cable plant have different chemical, laser and ergonomic exposures, so add lines for those hazards.

Add site-specific items such as laser safety or solder fume extraction
Check records as well as the physical condition
Photograph each finding
Assign an owner and a due date to every gap

Reading the result

A high percentage does not guarantee a safe site, because the items are not weighted by risk. Read the critical items first. Then look at patterns: repeated housekeeping findings suggest a process or staffing problem, while repeated guarding findings may point to maintenance practices or production pressure. Track the percentage and the number of open actions per month alongside lagging indicators such as TRIR, so you see whether prevention is improving.

Common mistakes

Frequent errors are auditing only on a quiet day, relying on a single auditor who stops noticing familiar problems, and leaving findings without owners. Another is recording only negative findings, so there is no evidence of what is working. Close findings with verification, not just a note that someone was told. If you manage audit findings in a spreadsheet, link them to work orders so corrective maintenance is scheduled and tracked.

Frequently Asked Questions

How often should a safety audit be done?

Many plants do a short area walk weekly or monthly, with a fuller management audit each quarter or year. High-hazard areas deserve more frequent checks. OSHA requires some inspections on set schedules, such as annual LOTO inspections.

Is this checklist enough for OSHA compliance?

No. It is a screening tool for common issues. OSHA standards contain many more requirements, and your hazards may differ. Use it with your safety program, site hazard assessments and the standards that apply to you.

What is a critical finding?

A condition that could cause serious injury or death if it is not corrected, such as a bypassed interlock, a blocked exit, or work without energy isolation. Fix or stop the work immediately and document it.

Who should perform the audit?

A trained person with knowledge of the process, ideally with a worker from the area. Rotating auditors between departments gives fresh eyes and builds shared ownership.

If audit findings should become tracked maintenance work orders automatically, we can help connect your safety checks to your ERP or CMMS.

Talk to an Expert Explore More Free Tools

Related Tools

Safety & Workforce

More Safety & Workforce tools

See all

Workplace Safety Audit Checklist for Manufacturing