Maintenance Strategy for an Emergency Lighting System

 

Consideration 1

Term / Abbreviation

Definition

API

Active Pharmaceutical Ingredient

ATEX

Sky Explosible (French acronym)

CAT

Category

CCTV

Closed-Circumference Television

cGMP

Prevalent Good-tempered-tempered Manufacturing Habit

CMMS

Computerised Subsistlihood Superintendence Classification

CSE

Confined Space Entry

CTU

Convenient Experience Individual

Ex

Explosion shelter capacity displayed on equipment that is decent ce truth in an ATEX area

FT

Facilities Technicians

HR

Human Media

HSA

Vigor And Insurance Authority

HSE

Health, Insurance and Environment

IR

Industrial Relations

IS

Irish Edictl

IFM

Integrated Facilities Superintendence

KPI

Solution Deed Indicator

LEL

Lower Explosive Limit

LVI

Liquid Vapour Incinerator

NIPBI

Novartis International Pharmaceutical Branch Ireland

NRL

Novartis Ringaskiddy Limited

MCB

Miniature Circumference Breaker

MEWP

Mobile Elevated Is-sue Platform

MTBF

Mean Duration Between Deficiency

MTTR

Mean Duration To Restore

PB1

Product Fabric 1

PB1A

Product Fabric 1 Annex

PB2

Product Fabric 2

PM

Preventive Subsistlihood

PU

Product Individual

QA

Quality Assurance

SAP

Computerised Subsistlihood Superintendence Classification truthd by Novartis

SOP

Model Easy Proceeding

TS

Technical Representations

VEIS

Veolia Environnement Industries Representations

 

Undivided could be cegiven ce thinking that compiling a subsistlihood superintendence ce an exigency inconsiderableing classification would be a trite substance to total.

This may perhaps be the material with a slender station fabric applyablewithstanding our investigate at Novartis was applyable a labor that could be lowerestimated.

The pristine man to opine is the lamina of the station at approximately 150 acres and that exigency inconsiderableing by its species permeates integral vacation and interspace. The promote is the great seriousness establishd on insurance which is lowerstandable when Seveso directives are circumstanceored in.

Adding to this was the circumstance that until VEIS arrived on station there was no material superintendence ce the subsistlihood of the exigency inconsiderableing classification. Once the surrender passed to VEIS, really balancenight, we ancestral the mammoth labor of restoring the classification to ample agency and ensuring regulatory yielding in victualss of deficiency and experienceing.

This entire was nature played quenched lower the expectant scan of material station staff that may applyable feel been openly grateful to the applyableion of an IFM gang’s coming on station.

There was restriction duration ce VEIS staff to comfort into their roles in this challenging environment. Needless to repeat the pristine six months on station were a baptism of courage (notwithstanding thankamply applyable in the real understanding!).

Besides extraneously-delay assuming deficiency and experienceing duties, the primal stages implicated bunch postulates on twain the quantities of inconsiderable propers give and the degree of restore is-sue required. The direct stage required contravention with suppliers to bunch ce tonnage provide. Ample reparation of the classification would then engage establish in tandem with ongoing deficiency and experienceing.

Regarding deficiency and experienceing, there was shabby leefashion ce VEIS to beget a customised track as the regulations in I.S. 3217 2013 are wholly prescriptive. We singly had to metaphor quenched the most effectual and causative fashion to encommission the required deed of such a insurance imperilled classification.

I believe the expertise required from VEIS was applyable to reinvent a arrangement of maintaining an exigency inconsiderableing classification. Instead it was to utensil a superintendence, where nundivided stoped antecedently, that is-sueed twain in victualss of yielding to regulations and ensuring apex availability of a insurance imperilled classification. On this face, we unquestionably entrusted.

Novartis Ringaskiddy Limited is an API manufacturing set located in Co. Cork Ireland.

It is totalot of the Novartis global vigorcare gang which is reasoned in Switzerland.

In January 2014, VEIS productive commission ce the victuals of an Integrated Facilities Superintendence coincide of 5 years duration. This encompassed the aftercited equipment/services:

  • Utilities – steam boilers, imported-quality compressors, imported-quality dryers, composure towers, inspire texture, clearsed inspire classifications.
  • Hard Representations – courage intimidate, exhalation baffling defeat classification, CCTV, roller shutter doors, clear compass sliding doors, abbreviate lifts, passenger and consignment elevators, exigency inconsiderableing.
  • Soft Representations – catering, clearing, undoubtfulty, landscaping, plague control, insidely sets.

This was the pristine luck into the quenchedsourcing of Facilities Superintendence representations by Novartis so there was a precipitous education incurvation ce entire unquiet.

My role with VEIS was Technical Team Edictrate with earliest commission balance Utilities and Hard Representations.

Our most introduce Labor was to utensil a Subsistlihood Superintendence ce station remote Exigency Inconsiderableing. This had oppressed into deficiency balance the years; primarily ascribable to a bankruptcy of a fast team to balancesee its subsistlihood – there had closely been an ad hoc track to experienceing and restore.

Besides my role as Team Edictrate, the VEIS subsistlihood miscellany consisted of 2 Facilities Technicians, twain with vigorous late electrical proof.

It was determined that upkeep of the Exigency Inconsiderableing classification would be ampley self-delivered with no quenchedside coincideor involvement.

Metaphor 1: Novartis Ringaskiddy Limited (Source: PM Bunch)

Metaphor 1 is an aerial aim of the Novartis Ringaskiddy Limited station (PM Bunch).

Consideration 2

A

Main Switch Compass

B

Pump House

C

Tank Farm

D

Solvent Recovery

E

LVI

F

Contractor’s Compound (referable in IFM coincide opportunity)

G

Contrivance Stores (referable in IFM coincide opportunity)

H

PB 2

I

PB 1

J

PB 1A

K

Impair Inspire

L

Utilities

M

Technical Representations

N

QA Labs

O

Warehouse

P

Canteen/HR/Administration

Q

NIPBI Labs

R

Certainty Gate House

Consideration 2 defines alphabetically labelled points in Metaphor 1.

Novartis Ringaskiddy Limited is material to Seveso directives. These directives are spread in establish to succor repressmate senior industrial accidents and determine that stations are skilful, in victualss of tally, ce when accidents supervene (European Commission, 2016).

Sites are categorised according to the sum of imperilled chemicals in storage (Lawlor Technology, 2015). NRL is an upper precedency Seveso station – there are up to 4000m3 of solvent chemicals stored on station.

There are to-boot diverse Zundivided 1 and 2 ATEX areas. The HSA (n.d.) defines these as:

“Zundivided 1 – That totalot of a imperilled area in which a flammable sky is mitigated to supervene in natural agency.”

“Zundivided 2 – That totalot of a imperilled area in which a flammable sky is applyable mitigated to supervene in natural agency and, if it supervenes, earn ssummit ce a condensed duration.”

Another pattern of a imperilled area is the Dryer Unloading area in PB1. During undoubtful product campaigns, there is the intercourse of Category 3 chemicals here. Avenue to the area is strictly prohibited during these durations. Continuity with unfair sums of Category 3 chemicals can feel sarcastic vigor consequences ce a special (Ader et al, 2005).

Becatruth of the aboundingly imperilled easy tenor of the exigency inconsiderableing classification, sure is-sue habits were imported ce the VEIS team on the Novartis station.

We were required to enucleate a arrangement declaration ce exigency inconsiderableing subsistlihood activities. This was criticismed by the HSE division and a station electrical engineer. Edits were effected where certain antecedent to definite laudation.

The truth or raiseing of cellular phones was prohibited at entire durations at NRL.

It’s price applyableing ce this employment the challenging IR environment that VEIS entered at the preparation of the IFM coincide. It was seen by divers on station that affecting to an quenchedsourced representation provider would termination in lay-offs ce NRL subsistlihood staff.

In existence VEIS were labored at entrusting in areas that were either anteriorly deficiencyed or bankruptcyed convenient control.

Until this realisation had faded in, apex choice and superintendence was required from the VEIS team in regulate to construct vindication from the material station staff.

During the primal stages of the VEIS team’s coming onsite, there was an ruled standpoint on entire miens of our commence. It was of superexcellent memorialification that the team displayed the upmost professionalism and superabundance to sure is-sueing habits at entire durations.

It was imported that, ce our subsistlihood superintendence to is-sue, ample coagency was ordinary from material station staff. This implicated constructing commission from twain superintendence and ‘floor’ staff.

The Novartis Ringaskiddy station, lower the fashion, functions as a bunch of closely autonomous areas. The product fabrics, utilities, depot, tank farm & impair inspire areas entire feel named superintendence teams who entire feel in alter shrewd applyablewithstanding detached differences in arrangements of agency.

As exigency inconsiderableing is a profit that features abutting the station, the VEIS team had to experience a fashion to compound to the varying cultural habits in regulate to frame our superintendence is-sue.

Engaging in a reverential and sometimes closely glozing fashion was the regulate of the day. Here are some of the bridges that had to be crossed:

Arrangement Declaration enucleatement

  • The arrangement declaration ce exigency inconsiderableing subsistlihood activities required reaim and laudation from twain the HSE arrangement insurance superintendent and PB1 electrical engineer.
  • The singular mien to this is that neither of the other couple station electrical engineers opted to reaim or comment the arrangement declaration applyablewithstanding nature giveed with it.
  • See Appendix A ce cbalance page of Arrangement Declaration.

Planning Contraventions

  • Aconstruct there was a difference here in that VEIS cultivated weekly subsistlihood planning contraventions in the PB2 product fabric merely.
  • This was to determine that product and subsistlihood coordinators were assured of upcoming is-sues. This evidently expanded past exigency inconsiderableing to entire VEIS connected subsistlihood.
  • It to-boot succored determine that the is-sue enjointers ce the fabric had past applyableice as media were compact in this area.
  • Ce other areas on station, email applyableification was tit to subsistly NRL staff of pending activities.

Client Contraventions

  • As totalot of our customer coincidement superintendence, we bunchd disunited monthly contraventions with solution staff from the PB1, PB2 and Technical Representations areas.
  • This supposing a ceum ce entire totaloties to direct opinions on any manifestations or in-truth the good-tempered-tempered intelligence stories.

KPI Score Card

Client interaction was imperilled here. See exception 13.0 ce unfair component.

ATEX areas

It was animate ce VEIS to construct the self-reliance of the client in our ability to is-sue surely and competently in the ATEX areas. As an embedded coincideor, we were material to past grave investigation than any sub-contractor that supposing representations to the client. An pattern would be the edictratefeiture of a Fluke Ex multi-meter that we made. This came at a absorb of €1000. Entire other electrical subsistlihood staff truthd the non-Ex €300 rendering.

Asset Chronicles

Individual exigency inconsiderable propers were applyable scheduleed on the NRL asset chronicles. The last roll the chronicles went to was the Convenient Experience Individuals. The Novartis engineers were conscious to feel a ample schedule of exigency inconsiderable propers intervening in the asset chronicles so it made understanding ce VEIS to co-operate-with them. Aiding the NRL engineers with this labor was applyable in the opportunity of the IFM coincide applyablewithstanding providing this representation did plenteous to thicken the intercommunity and papply institute commission. This was substantially a mini contrivance and implicated the aftercited activities:

  • Compiling the ample schedule of propers.
  • Listing the propers correspondently by symbol and by area.
  • ‘Redlining’ the inconsiderableing plans to mirror moved, removed or fantasticly fixed propers.
  • Confirming the punish CTUs, Distribution Consultations and MCBs.
  • Liaising with the station electrical engineers to coincide on a naming/tagging session.
  • Supplying redlined inconsiderableing plans to station cunning station ce printing and uploading to the Novartis COMOS classification.

Station Manual (Play Tome)

A station manual or ‘play tome’ was enucleateed which quenchedlined the opportunity of the VEIS IFM coincide. This was a subsist muniment which evolved as the coincide progressed and mirrored any fantastic representations that were pretended to the surrender of VEIS. The station manual was material to durationic reaim by the Novartis IFM edictrate. Elevated roll subsistlihood strategies were to-boot stored in in this tome.

In regulate to integralow with dense onstation HSE policies, VEIS technical staff required training/certification with the aftercited:

  • ATEX Assuredness.
  • Exigency Inconsiderableing Commissioning & Deficiency.
  • Confined Space Entry.
  • Mobile Avenue Tower galaxy.
  • Prevalent Good-tempered-tempered Manufacturing Habit.
  • Courage Watch.
  • Lock-out/Tag-out/Isolation.
  • Mobile Elevated Is-sue Platform agency.
  • Permitting – violent and inunanalogous is-sues.
  • SAP CMMS
  • User roll ce FTs.
  • Livelihood Planner roll ce Technical Team Edictrate.
  • Agoing at Summits.
  • Manual Indexling.
  • Insurance Hamper.

As anteriorly mentioned, the Exigency Inconsiderableing classification had oppressed into a say of disrestore on the Ringaskiddy station. With the coming of VEIS onstation as the IFM provider, a fantastic succeed was spread on restoring the classification to ample easy regulate and maintaining it to a own and prompt edictl.

In pointation, it was quickly applyableiced by the VEIS team that schedule of exigency inconsiderable propers in the coincide mild was applyable punish. There had been diverse pointations and modifications to the classification withquenched own archives to mirror the changes.

After a mightful appraisal, it was root that past than €100,000 would be required in tonnage purchasing to raise quenched the certain restores. This would feel to be actioned by VEIS as it was among opportunity of the coincide.

Appendix B schedules the absorbs of tonnage required to conclude a ampley functioning exigency inconsiderableing classification.

Entire of the exigency inconsiderable propers on the NRL station are of the Self-Contained Exigency Luminaire incommensurate.

This symbol is defined as having entire components such as the lamp, control individual and battery either insidely or applyable past than undivided metre from the proper (Ventilux, n.d.).

8.1 Various Symbols Truthd

Figures 2 and 3 demonstration twain the most commmerely truthd and most elevated-priced to reestablish propers truthd at NRL.

There are other symbols to-boot such as ‘Exit/Running Man’ and ‘Twin Spot’. Although these are homogeneous imperilled from a insurance perspective, they came at a ingredient of the absorb to re-establish.

It was determined becatruth of the preferential pricing conducive ce purchasing total Stahl propers that these would be truthd to reestablish wanting CEAG individuals that were economically unrepairable.

CEAG propers were kept in representation merely when the restores didn’t augment past tube and battery re-establishment.

Metaphor 2: Stahl Ex Exigency Inconsiderable Proper (Source: Stahl)


Metaphor 2 demonstrations the symbols of Stahl inconsiderable propers truthd on the Novartis station (Stahl).

Metaphor 3: CEAG Ex Exigency Inconsiderable Proper (Source: Atex)

Metaphor 3 demonstrations the symbol of CEAG inconsiderable proper truthd on the Novartis station (Atex).

8.2 Quantities of Propers by Area & Zone

Consideration 3

Proper Symbol

Ex Zundivided 1

Ex Zundivided 2

Sure Area

Main Switch Compass

6

Pump House

15

Tank Farm

28

57

28

Solvent Recovery

33

69

LVI

16

35

PB 2

563

130

PB 1

530

145

PB 1A

285

78

Impair Inspire

58

31

Utilities

55

Technical Representations

95

QA Labs

88

Warehouse

93

Canteen/HR/Administration

125

NIPBI Labs

168

Certainty Gate House

7

Sub Totals

1455

219

1064

Grand Total

2738

Consideration 3 schedule the punished sums of inconsiderable propers by zundivided and by area.

The past punish fashion to class equipment decent ce truth in Ex Zundivided 1 and Zundivided 2 areas is by CAT 2 and CAT 3 respectively. However it is natural in Industry to wholeusion them by Ex Zundivided bulk merely.

Sure Area applys to symbol of inconsiderable propers truthd quenchedside of the imperilled areas.

8.3 Components Deficiency Applyable attribuconsideration attribuconsideration attribuconsideration attribuconsideration attributableification

The undivided profit of preamble on a dilapidated classification, from a subsistlihood perspective, is that you feel the postulates to index on the reasons why the effects feel failed. Metaphor 4 displays a breakdown of these deficiency edicts ce the exigency inconsiderable propers on the Novartis station.

This applyable attribuconsideration attribuconsideration attribuconsideration attribuconsideration attributableification was a solution driver in deciding the sums and symbols of disposable tonnage to be held on station.

Metaphor 4: Reasons ce Inconsiderable Proper Deficiency

Metaphor 4 illustrates deficiency postulates compiled on the NRL station.

The Deficiency and Subsistlihood activities evolved as the coincide progressed on the Novartis station. The primal stages intervening of deficiency and postulates bunch. This past to deficiency, experienceing and restores.

9.1 Structure and Administration of PMs on CMMS

Novartis utilises the SAP CMMS to administrate entire of its subsistlihood activities. VEIS staff were interpretationful onstation in the truth of this classification. The Facilities Technicians were interpretationful to

User roll opportunity the Technical Team Edictrate was interpretationful to Planner roll.

As effectual owners of the effects and classifications that were in opportunity ce the IFM coincide, it was coincided that we would control subsistlihood activities end-to-end.

Here is a abstract of how we ran this mien of our agency ce the exigency inconsiderableing classification:

  • PMs were built over the Asset IDs of the CTUs.
  • The CMMS Begetd a PM01 Repressmateive Subsistlihood Is-sue Regulate in track of the Ascribable Date reasoned on the Centire Horizon settings.
  • The VEIS Planner Released the Is-sue Regulate in track of the essence nature carried quenched.
  • Undivided of the FTs printed the terminationant Job Card.
  • The FTs had a predetermined duration of duration from the Ascribable Date to total the essence so as applyable to abound the Late Date.
  • PMs that balancesviolent the Late Date required Deviation Fames to be submitted.
  • Corrective activities were chronicled using PM11 Deferred Subsistlihood or PM12 Introduce Subsistlihood Is-sue Regulates depending on the severity of the manifestation.
  • Completed Job Cards and fames, where pertinent, were uploaded to the CMMS and fast to the pertinent Is-sue Regulate antecedently changing its condition to Total.

See Appendix C ce definitions of the victualss truthd by the SAP CMMS.

See Appendix D ce an pattern of a Novartis Is-sue Regulate influential on the SAP CMMS.

9.2 Permitting ce Is-sues

There was difference abutting the NRL station in how enjoins to is-sue were arrangemented. Aconstruct it was an pattern of how at a elevated roll there was edictl habit applyablewithstanding the existence on the reason was unanalogous.

This was another area where VEIS had to compound to the unanalogous proceedings and determine twain insurance yielding and a durationly fashion ce entrusting is-sues. The duration regard stems from tedious delays that could supervene if undivided did applyable flourish the unfair enjointing guidelines ce a totaloticular area.

See Appendix F ce a consideration displaying the differences per area in arrangementing of enjoins to is-sue on the NRL station.

9.3 Deficiency and Experienceing

Daily Experience

The aftercited is the proceeding populated ce the daily experience:

  • To total the daily experience of the exigency inconsiderableing classification, undivided of the Facilities Technicians treads the station and represss the CTUs ce intercourse of any omissions.
  • Permitting is applyable required ce this essence.
  • Any omissions are chronicled in the VEIS Exigency Inconsiderableing Logtome and restores are spread into the is-sue queue.

Visual Deficiency of Exigency Inconsiderables

Lower the anterior I.S. 3217 edictl, entire exigency inconsiderable propers had to be visually inspected weekly. This would feel been neighboring impracticable ce the VEIS team to entrust.

The prevalent edictl stipulates that 25% of propers are to be visually inspected weekly terminationing in 100% nature repressed in a disgusting week duration.

The aftercited is the proceeding populated ce the visual deficiency:

  • When commenceing a visual deficiency of the exigency inconsiderables in an area, the Facilities Technicians earn pristine continuity the area director to impart them of the cunning to raise quenched an deficiency.
  • A enjoin and countersigspecies earn then be requested if it is reckoned certain.
  • Technicians earn truth the avenue card swipe-in classification or the memorial-in logtome when entering the area if such classifications are give.
  • The Technicians earn then tread the area and chronicles their terminations in the VEIS Exigency Inconsiderableing Logbook.
  • The area earn be left in a clear and orderly say.
  • They earn swipe or memorial quenched when leaving the area if such classifications are give.
  • If a enjoin was ordinary then it earn be returned and memorialed impromptu.
  • See Appendix E ce Risk Assessment consideration.

Three Monthly Deficiency (ce a 3 hour self-contained classification)

The aftercited is the proceeding populated ce a 3 monthly deficiency:

  • When commenceing the Three Monthly Deficiency of the exigency inconsiderables in an area, the Facilities Technicians earn pristine continuity the area director to impart them of the cunning to raise quenched an deficiency.
  • A enjoin and countersigspecies earn then be requested.
  • Signs earn be establishd at the entrances to the area to admonish specialnel that an deficiency is preamble establish.
  • Technicians earn truth the avenue swipe-in classification or the memorial-in logtome when entering the area if such classifications are give.
  • The exigency inconsiderableing Convenient Experience Individual earn then be activated, or in materials where a circumference is applyable on a CTU, the MCB earn be switched impromptu which earn termination in the exigency inconsiderableing going into omission edict.
  • The Technicians earn then tread the area and chronicles their terminations in the VEIS Exigency Inconsiderableing Logbook.
  • When total the CTU earn be reset and any MCBs that were switched impromptu earn be switched on.
  • Faults that feel been chronicled earn then be addressed.
  • A decent ladder earn be truthd ce the restores.
  • Where the stalk ladder is truthd, FTs should applyable abound hip summit to the summit rung of the ladder.
  • A insurance hamper earn be exhausted where required.
  • A scaffold earn be truthd where required.
  • Care is to be engagen when using index tools.
  • A Violent Is-sue Enjoin earn be required to is-sue neighboring subsist unguarded tonnage such as using a meter to repress ce might.
  • If replacing insidely tonnage of the inconsiderable or where a wiring omission needs to be rectified, then the circumference earn be locked quenched at the inconsiderableing provide consultation with a MCB locking expedient and a padlock. VEIS staff earn apply to Novartis SOP 000.926.0479 – Isolation of electrically driven equipment.
  • Antecedently disconnecting any cable the FT must frequently substantiate that the insidely mains wiring is ‘dead’ using a digital multi-meter.
  • When is-sue is total then the area is to be left clear and orderly and entire circumferences should be mighted up.
  • They earn swipe or memorial quenched when leaving the area if such classifications are give.
  • The enjoin earn be returned and memorialed impromptu.
  • See Appendix E ce Risk Assessment consideration.
  • Upon collection of the Three Monthly Deficiency and experienceing, a fame ce deficiency, experienceing and servicing as componented in Annex C1 and Annex C7 of I.S. 3217:2013 shentire be fast to the pertinent SAP Is-sue Regulate where it can be aimed/printed by the PU Superintendent and electrical engineer of (PB1,PB2,TS). As per 16.2.4.1 of I.S. 3217:2013. A representation of the fame shentire be establishd in the VEIS Exigency Inconsiderableing Logbook.

Annual Commit Experience (ce a 3 hour self-contained classification)

The aftercited is the proceeding populated ce the annual commit experience:

  • When commenceing the Annual Commit Experience of the exigency inconsiderables in an area, the Facilities Technicians earn pristine continuity the area director to impart them of the cunning to raise quenched an deficiency.
  • A enjoin and countersigspecies earn then be requested.
  • Signs earn be establishd at the entrances to the area to admonish specialnel that an deficiency is preamble establish.
  • Technicians earn truth the avenue swipe-in classification or the memorial-in logtome when entering the area if such classifications are give.
  • The exigency inconsiderableing Convenient Experience Individual earn then be activated, or in materials where a circumference is applyable on the CTU the MCB earn be switched impromptu, which earn termination in the exigency inconsiderableing going into omission edict.
  • The Technicians earn then tread the area and chronicles their terminations in the VEIS Exigency Inconsiderableing Logbook.
  • When total the CTU earn be reset and any MCBs that were switched impromptu earn be switched on.
  • Faults that feel been chronicled earn then be addressed.
  • A decent ladder earn be truthd ce the restores.
  • Where the stalk ladder is truthd, Technicians should applyable abound hip summit to the summit rung of the ladder.
  • A insurance hamper earn be exhausted where required.
  • A scaffold earn be truthd where required.
  • Care is to be engagen when using index tools.
  • A Violent Is-sue Enjoin earn be required to is-sue neighboring subsist unguarded tonnage such as using a meter to repress ce might.
  • If replacing insidely tonnage of the inconsiderable or where a wiring omission needs to be rectified, then the circumference earn be locked quenched at the inconsiderableing provide consultation with a MCB locking expedient and a padlock. VEIS staff earn apply to Novartis SOP 000.926.0479 – Isolation of electrically driven equipment.
  • Antecedently disconnecting any cable the FT must frequently substantiate that the insidely mains wiring is ‘dead’ using a digital multi-

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