Question

Case Study #5 - Audit Engagement - Operational Safety Audit AFR Manufacturing Company's senior management asked the internal audit function to conduct an operational safety audit of the production facility's metal drill press unit. More specifically, the internal audit function was asked to determine how well the metal drill press equipment and equipment operators comply with company safety policies. Five downtime injuries of drill press operators occurred in the last six months. The total downtime for the five injuries was 37 hours. Management estimated that the drill press downtime, and the resultant decrease in overall productivity, reduced revenue by approximately $265,000. In addition to the downtime injuries, two drill press operators experienced detectible hearing loss during the six-month period. The internal auditors learned that the company's safety policies include the following: Operators are required to wear safety glasses, ear plugs, and protective gloves. The drill presses are required to have a clear, plastic safety shield and a protected channel to safely feed the metal through the press. * The drill is operated by a knee switch. The operator engages and disengages the drill by shifting his or her right knee. The internal auditors found the equipment to be in relatively poor condition with little evidence of any regular maintenance. Drill bits were not replaced as they became dull, and broken bits often were used because new bits were not kept in supply. Two of the 10 drill press machines were missing safety shields. Five of the 10 machine operators were using the protective ear plugs at the time the auditors visited the plant and six were wearing safety glasses. Four of the knee switches were found to be sticking occasionally in both the off and on positions. The auditors perceived a general sense of negligence-negligence by production management, drill press equipment operators, and maintenance employees.

Answer 1

1. Internal Audit Engagement Objective: This engagement is conducting an operational safety audit for the metal drill press unit. The audit committee's objectives is to assess whether the company's equipment operation fulfills the safety policies of the company.

2. Audit Observations:

Conditions: Following conditions represent the current state of the company:

• The drill bits were not maintained in good condition. It was very dull and there was very less supply of the drill bits.
• The knee switches were not in the right position.
• The machine operators were not wearing protection equipments.

Criteria: Following criteria represent the correct state of the company:

• Following accessories should be worn by operators mandatorily:

a) Safety glasses

B) Ear plugs

c) Protective glasses

Consequences: following are the consequences of the existing conditions and the criteria:

• Five injuries are sufferred due to non-adhering to safety policies.
• The company sufferred a big loss during the 6 months period.
• Overall reduction in productivity and company's revenue.
• The company incurred huge medical expenses and lawsuits facing due to injuries.

Causes: Following are the reasons for the condition and consequence of the condition:

• The company did not maintain proper procedures to maintain the equipment.
• The company is not concerned about the personnel safety and other employees.