Objective The aim of this study is to make full use of the audit database of QHSE system over the years, analyze the weak elements of management, make targeted management plan, and continuously improve the level of safety management.

Methods Using analytic hierarchy process (AHP), a hierarchical structure model is established, which takes risk analysis, risk degree, system audit element, and early warning element as the criterion layer, the base layer, the scheme layer, and the target layer, respectively. The degree coefficients of Grade Ⅰ, Ⅱ, Ⅲ and Ⅳ risk are determined according to the risk matrix. Combined with the system audit question list, the risk degree and average risk degree of each audit element could be calculated, as well as the weight of the risk degree of each audit element. Through the comprehensive calculation of the system audit database over the years and expert experience evaluation, the early warning conditions, early warning grades, and early warning countermeasures are determined comprehensively.

Results The method was applied to analyze the audit data of a management unit, and the early warning elements and targeted management suggestions were proposed in time. After the management unit strictly implements the management improvement plan, the scores of early warning elements in the audit process increased significantly in the next year, and the management effect was improved obviously.

Conclusions The introduction of early warning system in the process of QHSE system audit could facilitate the identification of the early warning elements, which would urge the management units to enhance the attention on the weakness of the management. This study has important referential significance for management improvement and production safety.