Please note: This presentation was held by Sudhir Gurtoo at the webinar series of EEPC, the premier trade and investment promotion organization in India. Some images have been removed due to copyright reasons.
2. Content
Background – Covid spread
Pre-preparation in Plant before opening
Starting from Home to Work
Health and Safety at Plant
Health and safety after reaching home
Emergency response dealing (team)
Monitoring Machinery, Utility health (with some Tips)
2Leadec | Manufacturing , Maintenance Services and Solutions | Covid Start-up 2020
3. Acknowledgements
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Leadec | Manufacturing , Maintenance Services and Solutions |
Covid Start-up 2020
State Governments
• Department of
Factories, Labor,
Industries, Police
• Department of Health
and Family Welfare
• District Administration
Government of India
• Ministry of Industries,
Commerce
• Ministry of Health and
Family Welfare
• CII
• Leadec Facility Team
• Toyota
• WHO
Others
4. Covid spread and protection
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Close
Contact
with
virus
Respiration
Person to Person Spread
Commonly TouchedSurfaces
Hands, Touching Eyes, Nose and
Mouth Frequently
Coughing, Sneezing andTalking
Temperature Screening
Social Distancing
Disinfection of commonly touched surfaces
Cleaning Hands with Soap & Water
or Hand Rub Sanitizer
Cough Etiquette & Use ofMasks
Source Means How to Protect?
WHO : World HealthOrganization
Social Distancing
Self Health Monitoring
5. Pre-preparation in Plant
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Covid Start-up 2020
DESIGNATED QUARANTINE AREA
In consultation with Medical staff, for
isolating employees identified during the
work-day in the Plant premises/Office.
from all employees on their travel and
health history. HR in consultation with
doctor to permit entry or recommend 14
days home quarantine from the date of
return.
EMAIL CONFIRMATION
PEST CONTROL / FUMIGATION
of entire premises, employee transport,
Forklifts/stackers and other critical areas,
wash-rooms, toilets, canteen, hand wash
areas etc.
DISINFECTION AND
SANITIZATION
of all common areas by properly PPE
equipped in-house teams.
MAINTENANCE AND EQUIPMENT
CHECKS
of Plant infrastructure, machines and
equipment.
ENSURE ADEQUATE STOCK OF PPE
including masks @ 1 per individual per day and
digital scanner thermometer
DESIGNATED COVID RESPONSE
TEAM
Create and announce a COVID
Response Team (HR, Operations,
Medical) to monitor Plant startup and
smooth operations
6. Starting from Home to Work
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S No. Particulars Measure
1 At Home Before Start of Work • Check and confirm your health status
2 Safety at Pick-Up Point
• Ensure social distancing and
respiratory hygiene/ mask
3 Travel in Bus: Alternative Seating • Ensure social distancing
4 Commutation Walk Path • Ensure social distancing
5 Locker Room Usage/Punch-in • Ensure social distancing
7. At Home Before Start of Work
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Purpose: Employees take ownership in declaring their health status
Now
• No self-examination on health status • Self-examination on health status
Key Points
• Start to office only when the employee is healthy
• If employee is feeling sick, having severe cough, sneezing and difficulty in breathing, stay
back at home. Take rest and consult family Doctor
• Report to supervisor and Company Doctor
Before
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8. Safety at pickup points
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Key Points
• Maintain social distancing instead of standing in group/crowd
• Cover face with mask
• If body temperature is more than 37.5ºC, team member is asked to go back to his home
• Not maintaining social distance
• No temperature check
• Maintain social distance at pick-up point
• Temperature check while boarding
Purpose: Ensure employees maintain social distancing measures and respiratory hygiene
Before Now
Before
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9. Travel in Bus
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Before
Purpose: Ensure Social Distancing
• Employees Sit Next to Each Other
Now
• Alternate Seating
Key Points
• Alternative seating to ensure social distancing
• Windows to be kept open
• Employees ensure respiratory hygiene by wearing mask
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10. Thermal Scanning at Gate for Personnel
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Installation of thermal scanner in
employee entry – 4 Nos/ per need
Instant and mass entry fever check
All Will be monitored by security
team
3 to 4 People can be
scanned-
Instant screening
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11. Commutation Walk path
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Before
Purpose: Ensure Social Distancing while moving from yard to work place
• Employees Walk closely
Now
• Employees maintain social distancing
Key Points
• Always follow social distancing between one employee to another in the Company
premises
• Please wait till the next person moves
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12. Locker Room
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Before
Purpose: Ensure Social Distancing while moving from yard to work place
• Employees uses locker in group
Now
• Employees maintain social distancing
• Maintain social distancing while using locker room
• Leave locker room immediately without flocking
• Wash hands with soap and water for 20 seconds before exiting from the locker room
Key Points
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13. Health and safety at company
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SOP No. Particulars Measure
1 Turnstile Gate (Entry & Exit) • Ensure social distancing
2 Food at Canteen • Ensure social distancing and hygiene
3 Canteen Staggered Timings • Ensure social distancing
4 Menu Changes • Ensure hygiene, simple menu
5 Attendance Swiping • Keep distance and sanitise touch pads
6 Exercise Before Shift Start • Ensure social distancing
7 Morning/Shift Beginning Meeting • Ensure social distancing
8 Work at Shop Floor • Wear mask and distancing
9 During Breaks in Shop Floor • Sanitize common touch points
10 Working at Office • Alternative seating; avoid central AC
14. Health and safety at company
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SOP No. Particulars Measure
11 Executive Car Travel • Social distancing, wear mask, temperaturecheck,
two per car
12 Meetings • Avoid in-person meetings. Use Virtual meetings
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Entry of Visitor/ Contractors/
Vendors
• Wear mask and temperature check
14 Emergency Response Team • Form a Team and activate
15. Canteen
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Exit Exi
t
ENTRY ONLY ENTRY ONLY
Food Serving Counters
Dishwashin
g Area
SampleSample
Key Point
• Stand in queue to collect food.
Do not touch any food items
while collecting from your
hand.
• Sit in alternative seats while
having breakfast, lunch, dinner
and snacks
• Do not talk loudly near the
food counters and at dining
table
• Stewards to wear personal
protective equipment
• Wash your hands thoroughly
with soap and water (both
before and after)
16. Working at Office
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Before
Purpose: Ensure social distancing, hand hygiene and respiratory hygiene
• Sitting side by side & opposite to each
other
• Air conditioner ON
Now
• Alternative seating
• A/C off- Door open- Ensure microfilter if
A/C is required
• Ensure social distancing. Ensure alternative seating. Wear mask to prevent infection
• Disinfect your laptop or desktop during shift beginning
• AC switched off with doors open for ventilation.
• If AC is required, then ensure microfilter (Micro 95) in the ACs, as applicable
OXOXO×
XOXOXO
Work desk
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Covid Start-up 2020
Key Points
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17. Meetings: At Rooms -> Virtual
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Before
Purpose: Ensure Social Distancing and avoid touching attendance terminals
• Sitting side by side & opposite to each
other
Now
• Virtual Meetings
• Stop physical meetings or gathering people
• Utilize meeting tools and conduct virtual meetings
Key Points
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Removed due to
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18. What to do after Covid case Identification
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19. Covid Emergency Response Team
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A Covid Emergency Team , consisting of Key Functions like Medical, HR ,
Operations and including a Senior Director/ Owner must be formed and announced
Ensure Medical room is equipped to handle a covid-suspect, walk-in
Tie-up with a hospital, ambulance availability is strongly advised.
Covid Team needs to scan and stay updated on External developments (Police,
City adminstration, Govt notices, Media updates etc)
Collect and Display all Key phone numbers
Team should discuss and plan …quarantine zones in Plant, if required later
Team should check implementation of all Sanitisation rules and discipline
Team should also Communicate key updates with all personnel- via Notices,
emails, Whatsapp
Do not miss information flow to Suppliers , Customers and support agencies . This
can be through a designated personnel example Purchase person
20. Health and safety in common touch
points
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SOP No. Particulars Measure
15 Disinfecting Vehicle • Disinfect before and after each shift
16 Rest Rooms Disinfecting • Increase frequency of disinfecting
17 Rest Rooms in Office • Social distancing and hand hygiene
18 Shower Area Usage • Shut for some time
21. Disinfecting Vehicle
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Before
Purpose: Ensure common transport safe for commuting
• Floor cleaning & removing dust
Now
• Disinfecting before and after each trip
• Disinfecting vehicle and cleaning to prevent infection
• PPEs to be worn by the cleaning staff
Key Points
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22. Rest Rooms: Disinfecting
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Before
Purpose: Ensure Social distancing & Hygiene practice
• Cleaning done one in 2 Hours
Now
• Cleaning done every hour
• Alcohol-based disinfectant used
• Frequent touch points disinfected
• Frequent touch points disinfection done
• Frequency of cleaning to be done every hour. Additional manpower deployed
• Personal Protective Equipment usage mandatory for cleaning staff
• Alcohol-based disinfectant utilized
Key Points
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23. Rest Room Usage
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Purpose: Ensure Hygiene in rest rooms
1.While Entering
Toilet
2. Using Urinals 3. Using commodes
Use alternative urinalsto
maintain socialdistance
Open the doorusing
your elbow/arm
(Do not use palm)
1.Wash commodeswith
water before and after
using
2.Remove the waterby
using tissue papers
4. After using Urinals&
Commodes
Wash your hands as per
the guideline with soap oil
1.Maintain social distance
2.Do not enter inside if it is
crowded.
5. While coming out
from Toilet
2.1 Waiting for urinals
1.Maintain socialdistance
while waiting for washing
4.1 Waiting for urinals
Open the door using
your leg &elbow/arm
(Do not use palm)
1
2
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24. Health and safety after reaching Home
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SOP No. Particulars Measure
5.1 Hand Wash
• Hand Wash with Soap and Water thoroughly
and frequently
5.2 When to Use Mask • Issue mask to every member
5.3
Increase Ventilation • Switch-off AC and ensure circulation of air
In the Lift • Avoid common touch points
5.4
If someone in neighborhood
gets infected by COVID-19
• Wear mask, ensure social distancing,seek
immediate support
If you have kids at home • Educate hand hygiene and use ofsanitizer
If you have elderly at home • Monitor health conditiondaily
25. Health and Safety at Home
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How to Hand
Wash?
Clean Hands to
Protect from
Infection
26. Health and safety “at home”
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27. Health and Safety at Home
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28. Precautions in Production Zone
• Since workforce maybe less at Start, need redistribute and balance workloads
• Social distancing may slow-down line speed, but essential to observe
• Sanitisation and Masks discipline to be checked
• Uniform – all to wear a fresh one each day; discard and wash on return
• Shoes- Keep outside home, if possible
• Centralised AC systems if used, may be reconsidered and avoided
• Ensure availability of First Aid and Covid prelim check facility in Med room
• Ensure all operators aware whom to contact, for Covid related query ( and post Covid
Response Team names and contact numbers)
• Also advised to get Plant equipment re-checked, before a long Shut-down
(few samples follow…)
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29. Special prechecks for Air Handling Units
– simply supported impellers
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Alert : Don’t panic if the vibration levels are high
Expected problem
If left unoperated for a long,
the shaft will bend as shown.
This creates high Vibration.
How to Combat:
Check for Vibration Levels
Reduce the speed of fan using
VFD (variable Frequency drive)
Reduction in speed will help in
reducing vibration levels
Allow the fan to run for 12 Hrs
(will vary according to situation)
Shaft bend will get normalized
Go back to normal speed once
the Vibration level comes within
range.
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30. Air handling Units – Air filter checks
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Purpose: To Avoid buckling of AHU Side walls
Expected problem
Since Static for a long- accumulation of duct will be more
If switched on in as it is condition, increases static
pressure to a greater extent
In case of double skin AHUs- Side walls might buckle
How to Combat:
Clean filters before start
Or, replace with spare filters
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31. Pre-heat for Refrigerant Chiller
Compressor
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Purpose: to avoid failure of compressor motor windings
Expected problem
If stalled for a long, the refrigerant might settle inside the
compressor in Liquid state
As liquid is non-compressible, if switched on, liquid
refrigerant will enter the compression zone.
Compressing Liquid refrigerant might damage the
mechanical component and intern electrical winding
How to Combat:
Switch on the oil heater for
about an hour before start
This will ensure any settled
liquid refrigerant gets converted
to gas due to heat
Increase in temperature of oil
ensures proper viscosity of
lubricant which will ensure
proper flow when pumped
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32. Guidelines for Pre-treatment process
Generally process contains dip stages and spray stages
Riser pipes & nozzles will have settlements due to long stoppage,
especially in Degrease and Phosphate stages
Very high possibility of settlements in plate type heat exchanger, which are
predominantly used in Degrease stages and Phosphating stages.
can be combatted by flushing with Nitric acids
for Degrease stages, it is better to open and clean manually
Bag filters / Strainers need to be cleaned before starting the circulation pumps at
Activation, Passivation, hot water spray stages
Demineralized water (Both spray and dip stages), since was stored for a long, the pH
value would be high, so suggest complete replacement of water
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33. Oven, conveyors, Chillers, Fans
Purging of compressed air line is required as accumulation of condensate water
might be in the air pipes. If unpurged, chances of entering the painting equipment
are high- Can lead to quality related issue initially
Inspect the latent conveyor tracks (like oven) and ensure it is free of any foreign
objects, which might block when restarting after shutdown.
Although filters of oven are cleaned well, there is always a possibility of residual
dust, which will come out, when the circulation fan runs continuously. Hence
process a dummy body with a coating of sticky compound (Compatible to paint &
crater defect free), though the oven.
Large fans to be inspected for blade blockage , dust accumulation and clean
filters . Suggest initial start at low speed
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34. 34
6 Plant Restart Support Services
Cross-functional team lead by Site Manager
Leadec | Restart Support Services | April 2020
Sanitization &
Disinfection
Lead
Leadec Site Manager
Leadec Site (PRSS) Manager
Leadec Site Manager
Virus Prevention &
Social Distancing
Lead
Maintenance
Commissioning
Lead
Internal Supply
Chain Support
Lead
Employee Access
Control
Lead
Signage and
Training
Lead
Work Practices,
and Materials
Engineering and
Installation
Routines and
Experience
Inventory Control
and Reporting
Tracking and
Monitoring
Education and
Awareness
35. Leadec | Manufacturing , Maintenance Services and Solutions | Covid Start-up 2020
Protect Yourself, Protect family and Work Safe!
Thank you
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