Restarting Operations after COVID- Lock-Down

Restarting Operations
after COVID-19 Lock-Down
April 2020
1Leadec | Manufacturing , Maintenance Services and Solutions | Covid Start-up 2020

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

Acknowledgements
3
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

Covid spread and protection
4
Covid Start-up 2020
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

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

Starting from Home to Work
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Covid Start-up 2020
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

At Home Before Start of Work
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Covid Start-up 2020
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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Safety at pickup points
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Covid Start-up 2020
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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Travel in Bus
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Covid Start-up 2020
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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Thermal Scanning at Gate for Personnel
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Covid Start-up 2020
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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Commutation Walk path
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Covid Start-up 2020
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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Removed due to
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Locker Room
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Covid Start-up 2020
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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Removed due to
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Health and safety at company
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Covid Start-up 2020
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

Health and safety at company
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Covid Start-up 2020
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

Canteen
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Covid Start-up 2020
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)

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
Covid Start-up 2020
Key Points
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Meetings: At Rooms -> Virtual
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Covid Start-up 2020
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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What to do after Covid case Identification
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Covid Start-up 2020

Covid Emergency Response Team
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Covid Start-up 2020
 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

Health and safety in common touch
points
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Covid Start-up 2020
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

Disinfecting Vehicle
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Covid Start-up 2020
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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Removed due to
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Rest Rooms: Disinfecting
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Covid Start-up 2020
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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Removed due to
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Rest Room Usage
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Covid Start-up 2020
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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Health and safety after reaching Home
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Covid Start-up 2020
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

Health and Safety at Home
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Covid Start-up 2020
How to Hand
Wash?
Clean Hands to
Protect from
Infection

Health and safety “at home”
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Covid Start-up 2020

Health and Safety at Home
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Covid Start-up 2020

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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Covid Start-up 2020

Special prechecks for Air Handling Units
– simply supported impellers
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Covid Start-up 2020
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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Air handling Units – Air filter checks
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Covid Start-up 2020
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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Removed due to
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Pre-heat for Refrigerant Chiller
Compressor
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Covid Start-up 2020
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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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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Covid Start-up 2020

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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Covid Start-up 2020

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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

Leadec | Manufacturing , Maintenance Services and Solutions | Covid Start-up 2020
Protect Yourself, Protect family and Work Safe!
Thank you
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Restarting Operations after COVID- Lock-Down

Restarting Operations after COVID- Lock-Down

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