Personal Protective Equipment (PPE) is crucial for maintaining the health and safety of workers in all kinds of industries. Whether you work in construction, manufacturing, healthcare, or any other industry that deals with hazardous materials or conditions, performing regular PPE compliance audits is essential for making certain your staff is completely protected and that the organisation complies with all legal requirements.

A PPE compliance audit involves checking that all necessary PPE is provided, used properly, maintained correctly, and meets all applicable specifications. This article offers a step-by-step strategy to carry out an effective PPE compliance audit, with examples from various industries that illustrate the main components.

What is a PPE Compliance Audit?

A PPE compliance audit is a planned assessment to ensure that an organisation complies with all legislation and standards regulating the provision and use of PPE. It generally involves examining the selection, use, maintenance, and disposal of PPE across all departments. Audits help discover gaps in safety procedures, ensuring compliance with regulatory standards, and reducing the risk of workplace accidents or violations.

Regular PPE compliance audits are essential for ensuring worker safety and avoiding large fines for noncompliance. In the UK, failure to comply with PPE regulations can result in prosecution under the Personal Protective Equipment at Work Regulations 1992 and its revisions, as well as the Health and Safety at Work Act 1974.

Step 1: Review Applicable Regulations and Standards

The first step in performing a PPE compliance audit is to research the regulations that apply to your particular sector. Regulations vary by industry, and it is essential to understand which ones apply to your organisation.

In the UK, the following are key regulations:

  • Personal Protective Equipment at Work Regulations 1992: These outline the requirements for employers to provide and ensure the proper use of PPE.
  • BS EN 397 (Head Protection), BS EN ISO 20345 (Footwear), EN 166 (Eye Protection), EN ISO 20471 (Hi Vis Clothing), and other industry-specific standards govern different types of PPE.

In construction, regulations mandate the use of hard hats, high-visibility clothing, and other safety measures to prevent injury from falls, flying debris, or accidents with heavy machinery. Compliance with these standards is enforced under the Health and Safety at Work etc. Act 1974 and associated regulations.

In the engineering sector, workers often face risks related to mechanical operations, electrical hazards, and chemical exposure. PPE such as flame-resistant clothing, eye protection, and hearing protection are critical, particularly in sectors like aerospace or mechanical engineering. Compliance with the Control of Substances Hazardous to Health (COSHH) regulations and electrical safety standards is essential.

Pro Tip: Make sure to access up-to-date resources from the Health and Safety Executive (HSE) website, which provides comprehensive guidelines for all industries. Here's a great guide for Respiratory PPE from the Health & Safety Executive.

Step 2: Assess Workplace Hazards

Next, do a thorough risk assessment of the workplace to identify any potential hazards that could require the use of PPE. This can help to ensure that the PPE in use is appropriate for specific risks that workers face.

  • Hazards in the manufacturing sector may include exposure to sharp tools, heavy machinery, and loud noise, all of which demand the use of specific PPE such as cut-resistant gloves, ear protection, and safety footwear.
  • Workers in chemical processing industries may be exposed to hazardous gases or liquids that require the use of personal protective equipment (PPE) such as chemical-resistant gloves, respirators, and eye protection.

Pay particular attention throughout the risk assessment to any new dangers that have developed since the last audit, such as the introduction of new machinery or materials.

Chemical exposure in the workplace can result in serious health conditions for workers who are not properly equipped with chemical-resistant PPE. As a result, there is significant legislation surrounding PPE in the workplace for chemical risks.

Step 3: Check PPE Selection and Distribution

After the dangers have been identified, the next step is to determine if the selected PPE is adequate for the identified risks. This involves checking:

  • Correct fit: PPE must be properly fitting to each employee to give full protection.
  • Certifications: PPE should fulfil all applicable standards (such as BS EN standards in the UK).
  • Condition: Look for evidence of wear and tear. Damaged PPE, such as cracked hard has or worn-out gloves, must be replaced immediately.

For example, in the construction industry, many organisations discover that workers are wearing inappropriate footwear for their job, which leads to foot injuries.

During an audit, ensure that all safety footwear is compliant with BS EN ISO 20345 and offers features applicable to your sector such as the correct toe cap type, slip resistance, oil/fuel resistance.

Improper or defective PPE, particularly in the condition of gloves and respiratory protection, can result in injury incidents. A proper audit would highlight the need to replace gloves that were not rated for the specific hazards of that workplace.

Step 4: Ensure Proper Use of PPE

The next step is to ensure that staff are using PPE appropriately. Even the best PPE is useless if not used correctly. At this stage, auditors should:

  • Observe workers on the job to ensure they are wearing PPE as needed.
  • Check that PPE is being worn correctly.
  • Speak with workers about any difficulties they've encountered when using PPE, such as pain or a lack of training.

In sectors such as healthcare, the use of incorrect PPE can be life-threatening. To protect against airborne contaminants, face masks must be worn and fitted properly. Failure to comply may result in the spread of illness with disastrous consequences.

Step 5: Inspect Maintenance and Storage Practices

Proper maintenance and storage of PPE are critical to ensuring its effectiveness. During an audit, verify that:

  • PPE is regularly cleaned and maintained according to the manufacturer's guidelines.
  • PPE is stored in a manner that prevents damage, such as keeping helmets and gloves in a dry, clean environment.
  • All PPE is maintained with records of maintenance, inspection, and replacement schedules.

For example, in the oil and gas sectors, flame-resistant clothing must be inspected on a regular basis for damage to ensure that it continues to provide protection. Similarly, respirators used in high-risk areas such as as mining need regular fit testing and filter replacement.

Step 6: Record-Keeping and Documentation

Documentation is a key part of a PPE compliance audit. Proper records should be kept regarding:

  • PPE issued to employees (who received what and when).
  • Maintenance schedules and records of when PPE was last inspected or replaced.
  • Incident reports related to PPE failures.
  • Maintaining accurate records is crucial to verifying compliance with PPE rules and preparing for any inspections by regulatory bodies such as the HSE.

Tip: Use digital technologies to streamline record-keeping, which can help ensure that audits are thorough and up to date.

Step 7: Employee Training and Feedback

Training employees on the correct use of PPE is vital to compliance. Your audit should assess whether all employees have received adequate training on:

  • The proper use and limitations of their PPE.
  • How to inspect PPE before use.
  • When and how to request new or replacement PPE.

In some industries, like construction and agriculture, it’s important to check whether workers are trained to use multiple types of PPE depending on their tasks.

Additionally, gather feedback from workers about any issues they experience with their PPE. Is it comfortable? Does it impede their ability to perform their duties? Feedback can help you improve compliance and worker safety.

Step 8: Implement Corrective Actions

Once the PPE audit is completed, it is important to implement corrective actions based on the results. These may include:

  • Replacing improper or damaged personal protective equipment (PPE).
  • Providing additional training to workers who are not using PPE appropriately.
  • Updating PPE to comply with current rules or better protect against emerging hazards.

Create a plan to address any gaps found during the audit and schedule follow-up audits to ensure continuous improvement.

Conclusion

A PPE compliance audit is essential for ensuring worker safety and remaining in compliance with UK regulations.

Whether you work in healthcare, construction, manufacturing, or another industry, following this guide will help you evaluate the effectiveness of your PPE program and uncover areas for improvement.

Regular audits are not only good practice, but also required by law to safeguard both the employees and your organisation.