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Welcome

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Welcome

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Presentation Transcript

  1. Welcome

  2. Agenda for 24th June 2011 • Introduction to Polypipe • Overview of Risk Management on Site • Site Tour • Question and Answer Session • Lunch

  3. General rules for Visitors • All visitors must be accompanied by Polypipe host at all times • High Visibility Clothing must be worn when on site (outside Main Office) • Visitors are requested to adhere to designated route at all times • Ear Protection MUST be worn when visiting Extrusion and Mixing area • No access between Extrusion Lines, Moulding Machines or Access to Mixers • Beware of moving vehicles – Fork Trucks Operate in all areas • Smoking only permitted in designated Smoking Shelter (by Main Office) • Any accidents or injuries must be reported to your host • In the event of the Fire Alarm sounding (continuous high pitch whistle) • follow your host to the Fire Assembly point and wait for instructions • No Photos without permission from Operations Director

  4. Corporate Overview • Formed in 1902 producing pitch fibre pipe • Started making plastic moulding in the 1960’s as trade moulder • ‘Terrain’ Brand was created in 1964 and became market leader for innovation and Quality • A few owners since 1904 – now owned by Polypipe (Largest plastics manufacture in UK) • Site activities include: • Full Administration for site, including IT, Finance, Sales, Technical, HR • Manufacturing Facility • Injection Moulding/Assembly/Prefabrication • Extrusion • Mixing • Engineering • Warehouse and Logistics

  5. Risk Management • Site categorised as a complex risk • We have an integrated Management system in place to manage risk and have developed a number of internal systems, procedures and control measures to minimise risks that can not be eliminated • Common Risks across site include: • Noise • Powered Vehicles/Transport • Working at Height • Pressure systems • Asbestos • Fire • Hazardous Substances • Lifting Equipment • Water control (Legionella) • Common Legislation: • Noise at Work • LOLER • PUWER • Fire Reform Order • Management Regs • HSAWA • COSHH • Manual Handling • Display Screen Equipment

  6. Management Manual Management Standards • The Management System documents how we operate and comply to our legal obligations as well as to the respective International Management System standards • ISO 9001 - Quality • The main principle behind ISO 9001 is to satisfy customer requirements and make improvements • ISO 14001 – Environment • The main principles behind ISO 14001 is to operate a Management System that identifies it’s Environmental Aspects (something that can have an impact on the Environment), it’s legal duties with respect to the Environment (e.g. obligations not to pollute) and puts in a framework to monitor it’s performance and set objectives to improve. • OHSAS 18001 - Safety • The main principle behind OHSAS 18001 is to systematically manage Health and Safety, in order to minimise risks to employees and others; structured compliance to legal requirements. • PAS 99 – Integrated Management System • The main purpose of PAS 99 is to demonstrated that the Management System in place is fully integrated (e.g. common approach and system ) • Independently audited by BSI twice yearly – Licences held for each standard

  7. Management Manual Responsibility Matrix One of the ways we engaged our management team was to clearly document their responsibilities and fully brief them in how they should comply Accident Reporting/Recording Housekeeping Accident/Incident Investigation HSE Training (including other training details) Alcohol and Drugs Lifting Operations, Working at Height Asbestos Manual Handling Catering Oil Storage Tanks Control of Hazards at Work (Permits) Personal and Respiratory Equipment (PPE and RPE) Control of Lead at work (CLAW) Pressure systems Control of Noise Project Management and CDM Dangerous Substances, Explosive Atmospheres – DSEAR Prevision and Use of Work Equipment Display Screen Equipment Risk Assessment Electrical Equipment Safe Storage of Materials Employee Involvement Scaffolding Environmental Control Security Equality Act Visitors Fire Safety Waste Management First Aid Water Systems Hazardous Substances (COSHH) Workplace Transport

  8. Responsibility Matrix – Compliance Details Dangerous Substances, Explosive Atmospheres The Dangerous Substance and Explosive Atmosphere Regulations 2002 (DSEAR) put duties on employers and the self employed to protect people from risks to their safety from fires, explosions and similar events in the workplace DSEAR Assessments have been conducted on site which concluded that there were no significant DSEAR risks present. A DSEAR map has been created to show all areas on site where potentially dangerous atmospheres can form. All these areas have suitable warning labels displayed Full list of COSHH substances List of potential DSEAR substances DSEAR Map of site Print Accountability

  9. Responsibility Matrix – Compliance Details Control of Noise Noise is a hazard that can cause harm – excessive noise can cause a loss of hearing with the damage being irreversible. Polypipe Terrain have a coherent Noise Conservation Policy with noise control Plans locally where noise levels are above current Legislation guidance All employees working in areas where noise levels are at or approaching the guidance levels have been briefed in the hazards and actions to take to reduce the risk of hearing damage. There are several Hearing Protection Zones across the site where Hearing Protection is required (see map below) Noise assessments are completed annually and action plans in place to reduce noise where ever possible Hearing Protection Map Noise Conservation Policy Overview of Noise Regulation Requirement Noise Plan - Factory Noise Plan - Mixing Control of Noise Regulation Print Accountability

  10. Risk Management Whilst there are a number of common hazards, risks and related legislation and controls for the site, each area has it’s own challenges When we go for site tour, we will see the whole of the Manufacturing and Warehousing operations, I have highlighted some points of interest and some potential insurance considerations in each area Site has a secured perimeter with electronic fob access to all entrances to prevent unauthorised visitors – we are close to housing and access for children has to be considered. We have security and CCTV, but we are a plastic manufacture and not a bank – low value bulky items. Waste is closely managed and located in centre of site under CCTV with minimal combustible material against buildings to minimise arson risk

  11. Visitor Site Tour Route 7 8 Points of Interest: 1 – Raw Materials Silos 2 – Mixing 3 – Regrind 4 – Chillers 5 – Extrusions 6 – Moulding 7 – First-off room 8 – Materials Laboratory 9 – Assembly 10 – Prefabrication 11 – Toolroom and Engineering 12 – Waste Management 13 – Test areas (optional) 14 – Warehouse (optional) 15 – Loading Docks (optional) 16 – Goods Inwards (optional) 17 – Pump room 9 11 6 5 10 12 4 13 15 14 3 2 17 1 16

  12. Raw Material Silos • Start of the manufacturing process at Aylesford • 9 Silos containing PVC Resin and Filler – both non-hazardous • 40T per silo – numerous deliveries per week • Silo’s located on edge of site to eliminate reversing of tankers and to minimise site • traffic – tankers drive straight through site on one way system • Other lower quantity materials (process aids and pigments) are delivered in 1T bags • and stored internally within the mixing plant • Insurance Perspective • Access to silo’s prevented – filling points and access ladders secured

  13. Mixing Department • Raw materials converted to PVC Dryblends (material we can process in production • machines) • Material mixed in two stage mixing process • Raw material delivered to hot mix via system of pipes • Material mixed – frictional heat generated / changes chemical make up of material • Next stage is cold mix – material is cooled in large mixer • Material is blown over to Extrusion Factory via pipework to factory silos • Each mix is approximately 225 kg – we process many thousands of Tones per year • Whole process is a computer controlled automated system • Some material converted into pellets for Injection Moulding Process • Insurance Perspective • Disaster recovery – if mixing plant stops for over a week, production will run out of material (suppliers in place to minimise risk) • Area is dusty – dust has small risk of explosion (not significant DSEAR risk) but does build up on cable runs and sprinkler heads – fire risk (cleaning regime in place to minimise risks) • Noise – area hearing protection zone

  14. Regrind Operation • Part of the Mixing Departments function • PVC can be reused – all scrap and rejects made in production are reground on site • Material reclaimed from the scrap is re-used back into production • Grinders are located in pit built into floor to minimise noise and aid manual handling • Material ground into chip for which can be processed directly back into production • Material can be ground into power and fed back into mixing process – closed loop • Insurance Perspective • Noise – area hearing protection zone • Manual Handling – product has to be manually fed into grinders .

  15. Production Chillers • Vital support function for Manufacturing operations on site • The manufacturing of plastic components required the plastic to be heated to allow it • to ‘melt’ and then be formed into desired shape • If overheated plastics will decompose and give of toxic fumes and become fire hazard • Plastic is a good insulator, so it will retain heat for long time • Chilled water is required to remove heat from the plastic as soon as it has been • formed into desired shape • Insurance Perspective • Disaster recovery – if chilling plant stops, production can not run or will be at significantly reduced rates (additional chiller capacity built into site so if one system goes down, alternate systems can be used) • Noise – area hearing protection zone .

  16. Extrusion Department • One of main production facilities at Aylesford • Material taken from silos (delivered by mixing) and fed into machine hoppers • Pigment added just before material enters machine • Material (powder) heated, mixed, compressed in heated screw and barrel to form • molten plastic (approx 200ºC) • Material passes through a die to form desired shape (pipe or profile) • Pipe/profilepasses through calibrator to set final size/shape • Pipe/profile then cooled • Pipe/profile then cut to size and packed (some in-line sockets if required) • Pipe/profile booked onto stock and moved into stock location in external yard • Insurance Perspective • Manual Handling – some manual handing involved • PUWER – complicated machines made up from several different parts, linked • Fire risk from purge • Tooling – tuned to our materials and machines – difficult to replace quickly (profiles unique to Terrain – Pipes common in industry) • Noise – area hearing protection zone

  17. Injection Moulding Department • One of main production facilities at Aylesford • Material taken from 1T bags (delivered by mixing) and fed into machine hoppers • Material (granules) heated, mixed, compressed in heated screw and barrel to form • molten plastic (approx 200ºC) • Material injected into fixed mould to form desired shape • Material held in mould to cool and set to final size/shape • Product then ejected from tool and packed • Product then booked onto stock and moved into warehouse • Insurance Perspective • Manual Handling – some manual handing involved • PUWER – large machines with up to 500T locking force • LOLER – tools can weigh up to 5T and are changed frequently (over 100 per week) • Tooling – unique to Terrain – difficult to replace and on long lead times • Noise – area hearing protection zone if over 2 hours

  18. First Off Room • Terrain products are know for their quality – strict rules are applied to all products manufactured at Aylesford Site • Before production is started, samples are taken and checked against known quality • criteria – checking is carried out under controlled conditions and records of all • measurements are stored – product have to pass all dimensional checks before it can • run and be packed • Physical checks are also performed each production run to ensure the product is • capable of performing as designed • Most tests are set by BSI kite mark requirements, but many have been introduced as • part of the ‘Terrain’ standard based on many years experience of product • performance in the real world • Insurance Perspective • If products are made correctly, less customer complaints and failures in service

  19. Materials Laboratory • Terrain products are know for their quality – strict rules are applied to all products manufactured at Aylesford Site • Over 100 tests methods are documented to cover the range of physical testing • performed on ‘Terrain’ products. These range from softening points, colours, water • absorption, weathering tensile strength…… • All designed to ensure product perform as required by our customers – in most cases • well beyond the requirements of national and international standards • Insurance Perspective • If products are made correctly, less customer complaints and failures in service • Some COSHH implications – use of acids and strong solvents .

  20. Assembly Department • One of sub production facilities at Aylesford • Where possible products are manufactured, checked and packed at the machines • Where assembly or packing operations take longer then machine cycles or specialist • equipment is required, products are processed though our Assembly department • Assembly runs on days only and once assembled, parts are packed, booked and • transferred to the Warehouse • Insurance Perspective • Manual Handling –manual handing involved • COSHH – some products are glued together

  21. Prefabrication Department • One of sub production facilities at Aylesford • Most plumbing applications can be outworked with the use of ‘standard’ fittings • available on the market • Terrain offer a specialist service – Technical department will design bespoke solutions • for customers and Prefabrication department will manufacture parts as required • Examples • If you need an 80º bend rather than a 90º bend • Soil stacks – same for multi unit projects • Insurance Perspective • Manual Handling –manual handing involved • COSHH – some products are glued together .

  22. Engineering Department • Vital support process to the site • Need to cover maintenance and repairs to production machines and tooling • Also need to maintain the structure of the site and ensure key systems are operational • A lot of work tied up with legislation and audit recommendations • Electrical – Fixed Wiring and PAT testing • Sprinkler and Hydrants – weekly inspections and checks – emergency response • Improvement actions from Risk Assessment and audits • Water control (Legionella) • Pressure Systems • Lubrication and Planned maintenance • Insurance Perspective • Sprinkler pump maintenance essential to confirm readiness and to keep cover • Maintenance on the structure of the site vital to ensure smooth running and reduction of risks • Some work is high risk – competence and controls need to be maintained .

  23. Waste Management • Waste can be one of biggest site risks • Incorrectly stored waste can become a fire and health risk • Co-disposal of hazardous waste is illegal • Terrain operate a strict waste management program across the site • Registered as a hazardous waste producer • Registered as a waste carrier (our own waste) • Recycling of Wood, Paper, metal, plastic, ink cartridges • Accounted for 19% of our environmental impact in 2010 • Over 1,000T of waste last year = 90kg per person per week • Dedicated waste streams in all areas • Located in middle of site under CCTV to ensure high level of management • Insurance Perspective • Fire/arson risk . Eco Balance

  24. Test Area • Part of the Quality Operation on site • Bespoke water rig to test product performance 93ºC and 20º 1,500 cycles • Walk in oven to check seal and cap performance for exported products • Artificial weathering laboratory – simulate any climatic conditions • Insurance Perspective • If products are made correctly, less customer complaints and failures in service • Some COSHH implications – use of acids and strong solvents .

  25. Warehouse • Warehouse used to store products ready for despatch to customers – most items are ex-stock so should be available on day of order • Three warehouse areas • Warehouse 1 – main warehouse – high level racks – wire guided man-up trucks • Warehouse 2 – Some Ventilation assembly, some local storage and packing • operation • Warehouse 3 – specialist storage and packing operation • Insurance Perspective • Fire loss – if fire was to occur – could be total loss • No hot working permitted in area • Sprinkler in roof and within racks (cat 3) • Fire inspections carried out regularly • Manual handling and LOLER – fork trucks

  26. Loading Docks • Part of Warehouse where vehicles are load and customers come to site to collect • 5 loading docks • 2 used for Export containers – pipes made to special length to fit • 1 used for express deliveries (next day service) • 2 used for main fleet – UK mainland deliveries • External products (pipes and gutters) are collated into delivery drops (bundles) • Internal products (fittings) are collated into delivery drops (pallets) • Products loaded and unloaded by fork trucks • Vehicles leave site each day with orders being despatched • Insurance Perspective • Manual handling and LOLER – fork trucks • Vehicles and customer drivers (non-English speaking)

  27. Goods Inwards • As well as our own manufactured products, we stock and sell a variety of purchased parts from other suppliers and other Polypipe companies • All deliveries are pre-booked • Products are checked when unloaded and then put to stock • Insurance Perspective • Manual handling and LOLER – fork trucks • Vehicles and supplier drivers (non-English speaking) .

  28. Sprinkler Pumps and Tanks • As part of our site fire response system we have a number of control measures and systems in place • Sprinkler pumps • Diesel, Electric + Jockey • Pumps run weekly • Valve sets checked monthly • 4 water storage tanks to supply 45 minutes of water at full capacity • Hydrant ring around site • Fire equipment in all areas • Fire alarms and smoke detectors across site • Evacuation drills practiced each year • Insurance Perspective • Requirement to have equipment installed, maintained and serviced .