Plant & Machinery Pre-Start Checklist - Your Complete Guide (2024)

As a responsible operator, running a pre-start check on your plant or machinery before you start the day is the best way to ensure the job gets done safely and without delay.

Undertaking a pre-start check on your machine before you start a days work, happens in three stages.

Step 1 - Visual inspections of important features prior to starting the machine

Step 2 - Visual & function tests while the machine is turned on but stationary

Step 3 - Testing the machine’s functions during a short drive

Within each of these steps there are activities that are common to all pre-start checks. We itemised them below and we then go into a few examples of extra items that are unique to those machine classes.

The following items are on all pre-start checklists for plant and machinery and are universal whether they are done on paper or electronically. We then review the slight tweaks you need to make in three pertinent examples - Pre-Start Checks for Excavators, Pre-Start Checks for Forklifts and Pre-Start Checks for Mobile Cranes.

Plant & Machinery Pre-Start Checklist - Your Complete Guide (1)

Step 1 - Before turning the machine on:

The following checks need to be made while the engine is off and we recommend that they are done in the following order.

Important Features

  • Inspect Hydraulic Lifts & Tilt Rams (if applicable) - are these lubricated and carry no damage?
  • Battery - are the bracket terminals secure and clean?
  • Are the battery electrolyte levels correct and caps in place?
  • Is the battery charge sufficient for a day's work?

After these steps there are then a bunch of machine specific steps that are unique to each class of machine that you will need to visually inspect prior to turning the machine on. This involves things like the tracks, booms, arms and ground engaging tools.

Safety Fittings and Features

  • Seat and Seatbelt - working and no damage?
  • Data Plate - is it readable?
  • Warning Decals - are they readable?
  • FOPS & ROPS - are they secure and in good condition?

Coolant, Oil & Fuel Levels

  • Engine Oil Level - correct?
  • Fuel - enough for the day?
  • Transmission Oil Level - correct?
  • Hydraulic Oil Level - correct?
  • Coolant Level Correct for temperature?
  • Fluid Leaks - ensure there are no fluid leaks under the machine

Attachment Security

  • Attachments like Buckets, Brooms, Spreader Bars etc - are they secure and the pins secure?
  • Is there any damage to attachments that is visible? Make a note
  • Ground Engaging Tools and surface (such as tracks, buckets etc) - is the cutting edge loose or worn?

At the end of these basic checks, plus the visual inspections you make that are specific to the machine you are checking, then it’s time to turn the key. Make note of how smoothly it started and whether it’s running well at the point of start.

Step 2 - After turning the machine on:

Now, it's time to get that machine purring and run through the final safety inspections.

General Functions (common to all machines)

Horn - does it work? And is there any issue with its volume?

Hand Controls - do they operate correctly?

  • Foot Pedals - are they clean and do they operate correctly?
  • Control Panel - are there any issues with warning indicators, lights and gauges?
  • Reversing Beeper - does the machine operate in reverse? And do the beepers work?
  • Lights - do they work? Can they operate on spot or drive mode?
  • Rotating Warning Light - is it operational?
  • Park Break - does it hold the machine on an incline?

After these general checks, we are going to run through a bunch of unique features with your machine - like operating the boom, bucket, rippers or GPS if these are fitted to the machine. We’ll discuss these below.

Step 3 - While driving the machine now:

To complete the final checks you need to drive the machine a small distance.

  • Is the steering working well with no undue noise/stress?
  • Steering clutches - is there no excessive play?
  • Creep - the machine doesn’t creep when controls are neutralised

Excavator Pre-Start Checklist

If you’re operating an excavator you need to do all the above pre-start checks. Then you need to add these extras into step 1 and step 2. Step 3 is universally the same for most machines (ie, you are testing how the machine drives and moves).

Step 1 Additions - Visual inspections before excavator is started

  • Check that the hydraulic cylinders are lubricated with no damage
  • Check the quick hit and pin - ensure that it’s not seized, has no damage and the clip is in place
  • Ensure the track chain has correct tension
  • Check the track grouser plates are not damaged

Step 2 Additions - Check while excavator engine is running

  • Check that the boom and dipper extend to full height
  • Check that the bucket tilts and crowds to full travel
  • Slew - ensure the boom slews correctly and to full travel, with a smooth motion
  • Auxiliary Hydraulics - check they are operating
  • Check any survey equipment or GPS that might be fitted

Step 3 - no change, continue as above

Plant & Machinery Pre-Start Checklist - Your Complete Guide (2)

Forklift Pre-Start Checklist

Even machines as prolific as forklifts (and, as relatively harmless when you put them in the context of big yellow earthmovers) need pre-start checks, and workers all over Australia are running this process every morning to ensure the machine is fit for purpose before driving it around all day.

Step 1 Additions - Visual inspections before forklift is started

  • Is the mast lubricated and carrying no damage?
  • Are the forks even, with no cracks, damage and square?
  • Are the tyres inflated - you should really measure their PSI
  • Wheels - are they in good condition with no cracks?
  • Does the gas cylinder have any leaks? Is the bracket secure?

Step 2 Additions - Check while forklift engine is running

  • Does the mast extend to full height?
  • Does the mast chain have equal tension on both sides?
  • Does the side shift move effectively to the left and right?
  • Are any of the moving parts making an unusual noise?
  • Do the foot brakes work?

Step 3 - no change, continue as above

Mobile Crane Pre-Start Checklist

Cranes are obviously one of the more dangerous items of plant and equipment so ensuring they are working correctly before operating is essential to site safety. As such, mobile cranes with s capacity over 10 tonne must be officially registered with Workplace Health and Safety authorities in most states.

Crane Operator Pre-Start Checks

  • Does the crane operator or rigger certify that the ground and working conditions are suitable for this mobile crane to conduct the required lift?
  • Does the operator or rigger certify that this crane is certified to lift the size of the load that needs to be lifted today?
  • Is this crane registered with workplace health and safety authorities and is its certification current?
  • If the crane is more than 10 years old, has it received a major inspection certificate?
  • Is the crane operator manual and load chart written in English?
  • Does the operator have both a crane or rigging ticket, and a working at heights certification?

Step 1 Additions - Visual inspections before crane is started

  • Have you inspected the wire ropes?
  • Is the boom working and without damage?
  • Is the hitch secure and with the chain?
  • Do the crane and lifting components have required markings and signage?

Step 2 Additions - Check while crane engine is running

  • Have you tested the emergency controls? Are they fully functioning?
  • Have you operated the safety switches and interlocks, including all limiting and indicating devices?
  • Does the boom extend to full height?
  • Does the boom slew to full travel?

Step 3 - no change, continue as above

Once these pre-start checks are complete you will know if there is a problem with the machine before you start work or if the machine is ready to go for the day. Safety is a must on site and doing these pre checks are one way you positively impact the safety on site. If you are a quality operator with a well maintained fleet, our hundreds of thousands of users love talking to guys like you. Click here to register as a supplier on iSeekplant for free.

Plant & Machinery Pre-Start Checklist - Your Complete Guide (2024)

FAQs

What is a pre start checklist? ›

In the most basic sense, a pre start checklist is an organised list of parts and pieces of equipment that need to be carefully checked prior to use. This document ensures the capacity of the equipment deemed to function well and is safe prior to use by workers.

What is the purpose of a pre start? ›

A pre-start inspection is a quick review to ensure that a task or item of equipment is safe to use. In order to ensure that the task or equipment is used safely, certain things should be included in a pre-start inspection, such as: Reviewing Safe Work Procedures or other instructions.

Why pre checks are important? ›

Where the checks are critical for safety, they are usually documented. Pre-start checks identify safety deficiencies, maintenance problems or damage before the equipment is used: Reducing the risk of accidents or failures during use.

What is included in plant and machinery? ›

Plant and Machinery means apparatus, equipment, machinery, pipelines, telecommunication tower fixed to earth by foundation or structural support that are used for making outward supply and includes such foundation and structural supports but excludes land, building or any other civil structures.

What happens at a pre-start meeting? ›

A pre-start meeting is an on site meeting that occurs before any work is undertaken on a development site. The purpose of a pre-start meeting is to ensure development is carried out in accordance with the conditions of development approval with minimal adverse impacts on neighbouring properties and the environment.

Why is it important to have safety checklist in the workplace? ›

Safety checklists provide a tool for determining possible workplace hazards and should be completed during inspections, reported on, used as a basis for safety recommendations and filed for record-keeping purposes.

How do you conduct a pre start meeting? ›

Below are a few simple tips and strategies to help get you started.
  1. Mix it up. Consider asking a different team member to present the prestart on a weekly rotation. ...
  2. Limit distraction. Our brains are easily distracted. ...
  3. Make eye contact. ...
  4. Ask questions. ...
  5. Encourage group reflection. ...
  6. Make it real. ...
  7. Ask for feedback and input.
25 Sept 2017

What are pre operational safety checks? ›

The pre-operational check covers a number of key components of the machine and helps to identify maintenance issues and repairs that may be required. It is important to assess the conditions observed during your inspection to determine the action required.

When should a pre use check be performed? ›

Pre-use inspections are required before use of any equipment that has a potential to result in a severe loss. A checklist is a simple way of formalising a safety inspection. A checklist gives an operator a consistent set of specific things to look for.

What is the advantage of conducting pre operation check up before using the tools and equipment? ›

The importance to you is to: Reduce the risk of injury to you due to defective equipment. Verify that the equipment you will operate is in safe working order.

How is PPE calculated? ›

PP&E is recorded on a company's financial statements, specifically on the balance sheet. To calculate PP&E, add the amount of gross property, plant, and equipment, listed on the balance sheet, to capital expenditures. Next, subtract accumulated depreciation. The result is the overall value of the PP&E.

Why is plant machinery called plant? ›

The best answer we could find was that 'plant machinery' comes from the meaning behind the word 'plant' itself. Taken from the latin 'plantare', it originally means 'to fix in place' or to 'drive into the ground'. The idea here is that plant machinery is considered a fixed asset.

Why is machinery safety important? ›

Moving machinery can cause injuries in many ways: People can be struck and injured by moving parts of machinery or ejected material. Parts of the body can also be drawn in or trapped between rollers, belts and pulley drives.

How do I prepare for pre start? ›

Tips for a Successful Prestart Meeting
  1. It pays to be organised and prepared. ...
  2. Go through your Shelford Homeowner's file. ...
  3. Get inspired. ...
  4. Consider layouts and measurements. ...
  5. Review your electrical plan. ...
  6. Set up new gas and electrical accounts. ...
  7. Organise your own supplied items. ...
  8. Bring finance and settlement information.
6 Jul 2020

How do you hold a toolbox meeting? ›

6 Keys to a Successful Toolbox Talk
  1. Keep it short. ...
  2. Focus on one topic relevant to the work being done that day.
  3. Get workers involved by asking questions or having them demonstrate safe work practices.
  4. Be sure to cover changes to the site or working conditions.
  5. Have employees inspect tools, equipment, and PPE.
21 May 2020

How can we run a toolbox meeting effectively? ›

5 Tips for an Effective Toolbox Talk
  1. Talk directly to your audience. Ensure the topic is relevant to your industry and job site. ...
  2. Keep it brief. ...
  3. Stay positive! ...
  4. Demonstrate your point. ...
  5. Tell a story, not a statistic.
20 Aug 2015

What is the main purpose of checklist? ›

Checklists have the objective of overseeing tasks or projects and ensuring nothing important is forgotten during execution. This way, you don't omit anything that might end up compromising your results. Additionally, they ensure activities are completed in orderly, organized fashion.

What is checklist example? ›

The definition of a checklist is a list of things that can be checked off as completed or noted. An example of a checklist is when you have ten things to do for work and you make a list of all of them and you check them off as you accomplish each of them.

How important is a checklist of tools and equipment before starting a task? ›

Creating a checklist requires you to break down all major tasks into smaller and more specific tasks. This makes us more comfortable and confident that all tasks will be done correctly, so we delegate more and become more productive.

Who performs the pre operational inspection? ›

The operator is responsible for performing the pre-operation inspection. If more than one operator is going to use the machine at different times in the same shift, they must each perform a pre-operation inspection, followed by function tests, before using the machine.

What is Operation check? ›

An Operational Check (Opscheck) test is a type of test that may be used to verify the repair at the end of a diagnostic session. They are useful in verifying the repair completed correctly addresses the symptom being diagnosed. The Operation Check is part of a test's type settings.

How do you check a forklift before an operation? ›

Check for leaks, cracks and visible defects everywhere on the forklift. Check mast chains visually; avoid the use of hands. Test mast chain tension by lifting the load backrest to eye level—the mast chains should be level and any tilting may signify stretching or broken rollers.

What checks should be completed prior to use of equipment? ›

quick checks before use (eg electric cable condition on hand-held power tools, functional testing of brakes, lights on mobile machinery) weekly checks (eg presence of guarding, function of safety devices, tyre pressures, and the condition of windows, mirrors and CCTV on mobile plant)

Which areas must you check as part of pre-use checks? ›

Things to Look for in a Pre-Use Ladder Check
  • Stiles Must be in Good Condition. Do not use the ladder if stiles are bent or split as the ladder could collapse.
  • Check the Feet. ...
  • Check the Rungs. ...
  • Check the Locking Bars. ...
  • Check the Feet. ...
  • Check the Stepladder Platform. ...
  • Check the Steps for Strength and Stability. ...
  • Check the Stiles.
16 Jan 2019

Which steps must be done at least daily before using a forklift? ›

Federal OSHA requires that forklift vehicles have to be inspected at least daily, or after each shift when used around the clock. You will find this requirement in the Powered Industrial Truck standard at 1910.178(q)(7). OSHA does not require that forklift inspections be documented.

Why is it important to perform routine check up and maintenance of the tools and equipment? ›

Routine maintenance is designed to help keep equipment, machines, and buildings operating optimally. If a particular piece of equipment needs lubrication, it may work at a slower rate and reduce the efficiency of an entire line.

What is the importance of identifying the condition of tools and equipment? ›

It is important to inspect and identify defective tools and equipment at home. Inspecting for damage is one of the best ways to ensure that your tool or equipment will be useful for you in future projects. Inspections detect problems early when they're easier and cheaper to repair.

What are the benefits of equipment inspection? ›

Proper equipment inspections reveal problems with equipment that would cause it to be unsafe.
...
Lowering the costs of workplace injuries.
  • Work delays.
  • Lost work time.
  • Re-staffing costs.
  • Increased Worker's Comp premiums.
  • Increased group health coverage premiums.
  • Fines.
  • Liability.

Is inventory a PPE? ›

The same goes for real estate companies that hold buildings and land under their assets. Their office buildings and land are PP&E, but the houses or land they sell are inventory.

What is PPE ratio? ›

Definition: This ratio tells you how many dollars of sales your company gets for each dollar invested in property, plant, and equipment (PPE). It's a measure of how efficient you are at generating revenue from fixed assets such as buildings, vehicles, and machinery.

What is PPE balance sheet? ›

(pi pi i) or property, plant and equipment. abbreviation. (Accounting: Financial statements) PPE is a classification on a balance sheet of a company's fixed assets, such as buildings, computers, furniture, land, and machinery, that are expected to be used for more than a year.

What are the 4 types of plants? ›

Types of Plants-Herbs, Shrubs, Trees, Climbers, and Creepers.

What is difference between plant and machinery? ›

The difference between plant and machinery is that generally machinery will have moving working parts, and plant will not (though computers and similar electronic devices are considered to be machinery, despite have no moving parts). The working parts of a machine are also considered to be machinery.

What is difference between plant and equipment? ›

Plant refers to the larger mechanical pieces of machinery which may be used on-site, such as a tower lift or compressor. The term equipment describes the smaller non-mechanical tools such as ladders and wheelbarrows.

What is the basic rule in machine safety? ›

Always follow the instructions given. Always wear machine-appropriate personal protection equipment (PPE). Closed toe shoes protect your feet from impact and falling items and also reduce the risk of slips. Full wrap goggles shield your eyes from debris that may escape the guarding.

How can you prevent machinery hazards? ›

Always wear PPE on the job. Avoid wearing jewelry, hair styles, or loose clothing that might get caught on machinery.
...
Personal Protection:
  1. Wear PPE, such as goggles, safety shoes and leather gloves.
  2. Long hair should be tied back or tucked under to avoid getting caught in machinery.
  3. Avoid wearing jewelry.

What are plant and equipment hazards? ›

Plant and machinery are present in most workplaces and working with moving plant or parts create exposure to the risk of injuries. The hazards associated with moving parts of machinery include the risk of crushing, shearing, entangling, trapping, hitting or abrading, or the uncontrolled release of pressure (energy).

What is a pre start health and safety review? ›

A PSR identifies hazards associated with the equipment, structure or process that could expose a worker to injury during routine operation. The goal of a PSR is hazard elimination or control before the apparatus, protective element, structure or process is started up or used in a factory.

What is a pre-use inspection? ›

Pre-use inspections are required before use of any equipment or work process that has a potential to result in a severe loss. This inspection must be recorded in a log that is kept on the equipment or near the process and be available for review.

When should a pre-use check be performed? ›

Pre-use inspections are required before use of any equipment that has a potential to result in a severe loss. A checklist is a simple way of formalising a safety inspection. A checklist gives an operator a consistent set of specific things to look for.

What is the advantage of conducting pre operation check up before using the tools and equipment? ›

The importance to you is to: Reduce the risk of injury to you due to defective equipment. Verify that the equipment you will operate is in safe working order.

What is PSR for equipment? ›

'PSR' stands for Pre-start Safety Review, also referred to as PHSR for Pre-start Health and Safety Review. When it comes to pallet rack systems, it's an inspection process and report done by a knowledgeable person to determine if the systems are safe for use.

What is a PSR report in engineering? ›

PSR*? *Projed Study Report. engineering reports whose purpose is to document agreement on the scoP..,g, schedule, and estimated cost of a project so that the project can be considered for inclusion in a future programming document such as the STIP.

Is a PSR mandatory? ›

A PSR is required at a factory that produces aluminum or steel or at a foundry that melts material or handles molten material to ensure that sections 87.3, 87.4, 87.5 and 88, subsections 90 (1), (2) and (3), and sections 91, 92, 94, 95, 96, 99, 101 and 102 are met. There are no exemptions to carrying out PSRs.

What should be included in the inspection checklist? ›

What should be included on the checklist?
  • Environment. dust, gases, fumes, sprays, lighting, noise, ventilation.
  • Buildings. windows, doors, floors, stairs, roofs, walls, elevators.
  • Containers. ...
  • Electrical. ...
  • Fire protection equipment. ...
  • Hand tools. ...
  • Hazardous products. ...
  • Materials handling.

What checks should be completed prior to use of equipment? ›

quick checks before use (eg electric cable condition on hand-held power tools, functional testing of brakes, lights on mobile machinery) weekly checks (eg presence of guarding, function of safety devices, tyre pressures, and the condition of windows, mirrors and CCTV on mobile plant)

What is the importance of inspection? ›

Inspections help management make key decisions, control costs, and protect the company. Inspections help prevent accidents and provide evidence of due diligence for liability protection.

Who is responsible for carrying out the pre shift checks immediately prior to use? ›

The responsibility for carrying these out falls to your operators but, do they really carry them out every time? They need to understand the importance and practicalities of completing these checks regularly and correctly. Pre-use checks should be explained to your operators as part of their basic training.

How do you check a forklift? ›

Check for leaks, cracks and visible defects everywhere on the forklift. Check mast chains visually; avoid the use of hands. Test mast chain tension by lifting the load backrest to eye level—the mast chains should be level and any tilting may signify stretching or broken rollers.

Which steps must be done at least daily before using a forklift? ›

Federal OSHA requires that forklift vehicles have to be inspected at least daily, or after each shift when used around the clock. You will find this requirement in the Powered Industrial Truck standard at 1910.178(q)(7). OSHA does not require that forklift inspections be documented.

What is pre Operational Safety How important is pre operational safety procedure? ›

Comprehensive Pre-Operational Check

In order to ensure that your machine is operating safely and efficiently, a proper pre-operational check is important. The pre-operational check covers a number of key components of the machine and helps to identify maintenance issues and repairs that may be required.

What is the first step to do before operating equipment? ›

Before using a piece of heavy equipment, operators should follow these nine tips:
  1. Tip 1: Educate before operating. ...
  2. Tip 2: Wear proper clothing. ...
  3. Tip 3: Understand the jobsite. ...
  4. Tip 4: Complete a visual check. ...
  5. Tip 5: Use three points of contact. ...
  6. Tip 6: Practice starting procedures. ...
  7. Tip 7: Exhibit proper operating techniques.
30 Oct 2015

Why is it important to perform routine check up and maintenance of the tools and equipment? ›

Routine maintenance is designed to help keep equipment, machines, and buildings operating optimally. If a particular piece of equipment needs lubrication, it may work at a slower rate and reduce the efficiency of an entire line.

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