Maintenance Strategy for an Emergency Lighting System

 

Consideration 1

Term / Abbreviation

Definition

API

Active Pharmaceutical Ingredient

ATEX

Sphere Explosible (French acronym)

CAT

Category

CCTV

Closed-Circumference Television

cGMP

Ordinary Good-natured-natured Manufacturing Usage

CMMS

Computerised Means-of-support Administration Scheme

CSE

Confined Space Entry

CTU

Accessible Exemplar Ace

Ex

Explosion guard class displayed on equipment that is equiconsideration restraint representation in an ATEX area

FT

Facilities Technicians

HR

Human Resources

HSA

Sanity And Insurance Authority

HSE

Health, Insurance and Environment

IR

Industrial Relations

IS

Irish Methodl

IFM

Integrated Facilities Administration

KPI

Solution Accomplishedment 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 Labor Platform

MTBF

Mean Occasion Between Insufficiency

MTTR

Mean Occasion To Relit

PB1

Product Architecture 1

PB1A

Product Architecture 1 Annex

PB2

Product Architecture 2

PM

Preventive Means-of-support

PU

Product Ace

QA

Quality Assurance

SAP

Computerised Means-of-support Administration Scheme representationd by Novartis

SOP

Model Careless Progress

TS

Technical Advantages

VEIS

Veolia Environnement Industries Advantages

 

Single could be restraintgiven restraint thinking that compiling a means-of-support manoeuvre restraint an strait digestibleing scheme would be a common stuff to consummate.

This may maybe be the predicament with a insignificant appointment architecture beside our question at Novartis was belongable a lesson that could be inferiorestimated.

The earliest man to think is the layer of the locality at closely 150 acres and that strait digestibleing by its sort permeates every withdrawal and interval. The succor is the colossal substance establishd on insurance which is inferiorstandable when Seveso directives are eventored in.

Adding to this was the event that until VEIS arrived on locality there was no true manoeuvre restraint the means-of-support of the strait digestibleing scheme. Once the pardon passed to VEIS, plainly balancenight, we ancestral the mammoth lesson of restoring the scheme to unmeasured product and ensuring regulatory docility in stipulations of slip and exemplaring.

This accomplished was substance played extinguished inferior the heedful regard of true locality staff that may belongable feel been openly pleasing to the belongableion of an IFM community’s parade on locality.

There was segregateiality occasion restraint VEIS staff to enjoyment into their roles in this challenging environment. Needless to judge the earliest six months on locality were a baptism of life (beside thankabundantly belongable in the plain typeificance!).

Besides directly lofty slip and exemplaring duties, the primal extents confused collocation basis on twain the quantities of digestible equitables bestow and the distance of relit labor required. The exhibit extent required parley with suppliers to collocation restraint calibre accoutre. Unmeasured renewal of the scheme would then admit establish in tandem with ongoing slip and exemplaring.

Regarding slip and exemplaring, there was abrupt leemethod restraint VEIS to fashion a customised advent as the regulations in I.S. 3217 2013 are accomplishedly prescriptive. We singly had to delineation extinguished the most causative and causative method to pronounce the required accomplishedment of such a insurance accurate scheme.

I think the expertise required from VEIS was belongable to reinvent a method of maintaining an strait digestibleing scheme. Instead it was to instrument a manoeuvre, where nsingle awaited anteriorly, that labored twain in stipulations of docility to regulations and ensuring apex availforce of a insurance accurate scheme. On this front, we unquestionably pronounceed.

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

It is segregate of the Novartis global sanitycare community which is naturalized in Switzerland.

In January 2014, VEIS conjectured business restraint the eatables of an Integrated Facilities Administration reduce of 5 years space. This encompassed the coercethcoming equipment/services:

  • Utilities – steam boilers, ghost compressors, ghost dryers, subsidence towers, breathe-into matter, clear breathe-into schemes.
  • Hard Advantages – life terrify, exhalation defiance scheme, CCTV, roller shutter doors, purified opportunity sliding doors, lop lifts, voyager and consignment elevators, strait digestibleing.
  • Soft Advantages – catering, purifieding, securety, landscaping, curse coerce, interiorly fixs.

This was the earliest speculation into the extinguishedsourcing of Facilities Administration advantages by Novartis so there was a abrupt knowledge deflexion restraint accomplished solicitudeed.

My role with VEIS was Technical Team Administer with original business balance Utilities and Hard Advantages.

Our most direct Lesson was to instrument a Means-of-support Manoeuvre restraint locality remote Strait Digestibleing. This had procumbent into insufficiency balance the years; chiefly attribuconsideration to a insufficiency of a dedicated team to balancesee its means-of-support – there had closely been an ad hoc advent to exemplaring and relit.

Besides my role as Team Administer, the VEIS means-of-support band consisted of 2 Facilities Technicians, twain with zealous gone-by electrical trial.

It was firm that upkeep of the Strait Digestibleing scheme would be unmeasuredy self-delivered with no extinguishedside reduceor involvement.

Delineation 1: Novartis Ringaskiddy Limited (Source: PM Collocation)

Delineation 1 is an aerial representation of the Novartis Ringaskiddy Limited locality (PM Collocation).

Consideration 2

A

Main Switch Opportunity

B

Pump House

C

Tank Farm

D

Solvent Recovery

E

LVI

F

Contractor’s Compound (referable in IFM reduce opportunity)

G

Purpose Stores (referable in IFM reduce opportunity)

H

PB 2

I

PB 1

J

PB 1A

K

Ruin Breathe-into

L

Utilities

M

Technical Advantages

N

QA Labs

O

Warehouse

P

Canteen/HR/Administration

Q

NIPBI Labs

R

Prophylactic Gate House

Consideration 2 defines alphabetically labelled points in Delineation 1.

Novartis Ringaskiddy Limited is material to Seveso directives. These directives are dispose in establish to succor bar greater industrial accidents and determine that localitys are easy, in stipulations of reply, restraint when accidents arise (European Commission, 2016).

Sites are categorised according to the whole of dangerous chemicals in storage (Lawlor Technology, 2015). NRL is an surpassing arrangement Seveso locality – there are up to 4000m3 of solvent chemicals stored on locality.

There are as-well disjoined Zsingle 1 and 2 ATEX areas. The HSA (n.d.) defines these as:

“Zsingle 1 – That segregate of a dangerous area in which a flammable sphere is mitigated to arise in ordinary product.”

“Zsingle 2 – That segregate of a dangerous area in which a flammable sphere is belongable mitigated to arise in ordinary product and, if it arises, get await restraint a abrupt determination.”

Another enunciatement of a dangerous area is the Dryer Unloading area in PB1. During indubiconsideration product campaigns, there is the neighboringness of Category 3 chemicals here. Adit to the area is strictly prohibited during these occasions. Contiguity with tiny wholes of Category 3 chemicals can feel keen sanity consequences restraint a idiosyncratic (Ader et al, 2005).

Becarepresentation of the yieldingly dangerous careless texture of the strait digestibleing scheme, secure labor usages were inherent restraint the VEIS team on the Novartis locality.

We were required to enunciate a method declaration restraint strait digestibleing means-of-support activities. This was critiqueed by the HSE branch and a locality electrical engineer. Edits were manufactured where indispensable coercemer to conclusive encomium.

The representation or conveying of cellular phones was prohibited at accomplished occasions at NRL.

It’s value belongableing restraint this employment the challenging IR environment that VEIS entered at the commencement of the IFM reduce. It was seen by multifarious on locality that frail to an extinguishedsourced advantage provider would product in lay-offs restraint NRL means-of-support staff.

In verity VEIS were lessoned at pronounceing in areas that were either earlierly insufficiencyed or insufficiencyed aditible coerce.

Until this realisation had corrupt in, apex pregard and contrivance was required from the VEIS team in regulate to construct repartee from the true locality staff.

During the primal extents of the VEIS team’s parade onsite, there was an firm standpoint on accomplished airs of our pass. It was of highest-rate consequence that the team displayed the upmost professionalism and give to secure laboring usages at accomplished occasions.

It was inherent that, restraint our means-of-support manoeuvre to labor, unmeasured coproduct was accepted from true locality staff. This confused constructing duty from twain administration and ‘floor’ staff.

The Novartis Ringaskiddy locality, inferior the exterior, functions as a collocation of closely autonomous areas. The product architectures, utilities, warehouse, tank farm & ruin breathe-into areas accomplished feel named administration teams who accomplished feel in deflect insinuating beside conspicuous differences in methods of product.

As strait digestibleing is a advantageousness that features over the locality, the VEIS team had to experience a method to adjust to the varying cultural usages in regulate to find our manoeuvre labor.

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

Method Declaration enunciatement

  • The method declaration restraint strait digestibleing means-of-support activities required rerepresentation and encomium from twain the HSE rule insurance overseer and PB1 electrical engineer.
  • The unusual air to this is that neither of the other couple locality electrical engineers opted to rerepresentation or promote the method declaration opposing substance bestowed with it.
  • See Appendix A restraint cbalance page of Method Declaration.

Planning Parleys

  • Aconstruct there was a strife here in that VEIS fertile weekly means-of-support planning parleys in the PB2 product architecture solely.
  • This was to determine that product and means-of-support coordinators were certified of upcoming labors. This explicitly stretched over strait digestibleing to accomplished VEIS connected means-of-support.
  • It as-well succored determine that the labor encourageters restraint the architecture had tardy belongableice as resources were fast in this area.
  • Restraint other areas on locality, email belongableification was enough to ready NRL staff of pending activities.

Client Parleys

  • As segregate of our customer promise manoeuvre, we collocationd disjoined monthly parleys with solution staff from the PB1, PB2 and Technical Advantages areas.
  • This granted a restraintum restraint accomplished segregateies to direct opinions on any ends or verily the good-natured-natured belongableice stories.

KPI Score Card

Client interaction was accurate here. See individuality 13.0 restraint favoring feature.

ATEX areas

It was animate restraint VEIS to construct the dependence of the client in our coercionce to labor securely and competently in the ATEX areas. As an embedded reduceor, we were material to past ardent sifting than any sub-contractor that granted advantages to the client. An enunciatement would be the coercionfeiture of a Fluke Ex multi-meter that we made. This came at a require of €1000. Accomplished other electrical means-of-support staff representationd the non-Ex €300 rendering.

Asset Proceedings

Individual strait digestible equitables were belongable registered on the NRL asset proceedings. The lowest plane the proceedings went to was the Aditible Exemplar Aces. The Novartis engineers were keen to feel a unmeasured proceedings of strait digestible equitables interposed in the asset proceedings so it made typeificance restraint VEIS to relieve them. Aiding the NRL engineers with this lesson was belongable in the opportunity of the IFM reduce beside providing this advantage did plenteous to thicken the homogeneity and aid raise duty. This was really a mini purpose and confused the coercethcoming activities:

  • Compiling the unmeasured register of equitables.
  • Listing the equitables correspondently by character and by area.
  • ‘Redlining’ the digestibleing plans to ponder moved, removed or upstartly domiciled equitables.
  • Confirming the redress CTUs, Distribution Considerations and MCBs.
  • Liaising with the locality electrical engineers to combine on a naming/tagging treaty.
  • Supplying redlined digestibleing plans to locality contrivance appointment restraint printing and uploading to the Novartis COMOS scheme.

Locality Manual (Play Dimensions)

A locality manual or ‘play dimensions’ was enunciateed which extinguishedlined the opportunity of the VEIS IFM reduce. This was a speed muniment which evolved as the reduce progressed and pondered any upstart advantages that were acquired to the pardon of VEIS. The locality manual was material to determinationic rerepresentation by the Novartis IFM administer. Excellent plane means-of-support strategies were as-well stored in in this dimensions.

In regulate to succumb with impenetrable onlocality HSE policies, VEIS technical staff required training/certification with the coercethcoming:

  • ATEX Certifiedness.
  • Strait Digestibleing Commissioning & Slip.
  • Confined Space Entry.
  • Mobile Adit Tower nock.
  • Ordinary Good-natured-natured Manufacturing Usage.
  • Life Watch.
  • Lock-out/Tag-out/Isolation.
  • Mobile Elevated Labor Platform product.
  • Permitting – fiery and dispassioned labors.
  • SAP CMMS
  • User plane restraint FTs.
  • Means-of-support Planner plane restraint Technical Team Administer.
  • Launched at Apexs.
  • Manual Employmentmanling.
  • Insurance Bind.

As earlierly mentioned, the Strait Digestibleing scheme had procumbent into a narrate of disrelit on the Ringaskiddy locality. With the parade of VEIS onlocality as the IFM provider, a upstart opinion was dispose on restoring the scheme to unmeasured careless regulate and maintaining it to a special and expeditions methodl.

In restoration, it was instantly belongableiced by the VEIS team that register of strait digestible equitables in the reduce frail was belongable redress. There had been disjoined restorations and modifications to the scheme withextinguished special proceedingss to ponder the changes.

After a mightful appraisal, it was build that past than €100,000 would be required in calibre purchasing to convey extinguished the indispensable relits. This would feel to be actioned by VEIS as it was amid opportunity of the reduce.

Appendix B registers the requires of calibre required to accomplished a unmeasuredy functioning strait digestibleing scheme.

Accomplished of the strait digestible equitables on the NRL locality are of the Self-Contained Strait Luminaire contradictory.

This character is defined as having accomplished components such as the lamp, coerce ace and battery either interiorly or belongable past than single metre from the equiconsideration (Ventilux, n.d.).

8.1 Various Characters Representationd

Figures 2 and 3 parade twain the most commsolely representationd and most consumely to reestablish equitables representationd at NRL.

There are other characters as-well such as ‘Exit/Running Man’ and ‘Twin Spot’. Although these are twin-fellow accurate from a insurance perspective, they came at a constituent of the require to rearrange.

It was firm becarepresentation of the preferential pricing available restraint purchasing accomplished Stahl equitables that these would be representationd to reestablish wanting CEAG aces that were economically unrepairable.

CEAG equitables were kept in advantage solely when the relits didn’t stretch over tube and battery rearrangement.

Delineation 2: Stahl Ex Strait Digestible Equiconsideration (Source: Stahl)


Delineation 2 parades the characters of Stahl digestible equitables representationd on the Novartis locality (Stahl).

Delineation 3: CEAG Ex Strait Digestible Equiconsideration (Source: Atex)

Delineation 3 parades the character of CEAG digestible equiconsideration representationd on the Novartis locality (Atex).

8.2 Quantities of Equitables by Area & Zone

Consideration 3

Equiconsideration Character

Ex Zsingle 1

Ex Zsingle 2

Secure Area

Main Switch Opportunity

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

Ruin Breathe-into

58

31

Utilities

55

Technical Advantages

95

QA Labs

88

Warehouse

93

Canteen/HR/Administration

125

NIPBI Labs

168

Prophylactic Gate House

7

Sub Totals

1455

219

1064

Grand Total

2738

Consideration 3 register the redressed wholes of digestible equitables by zsingle and by area.

The past redress method to rank equipment equiconsideration restraint representation in Ex Zsingle 1 and Zsingle 2 areas is by CAT 2 and CAT 3 respectively. However it is ordinary in Industry to regard them by Ex Zsingle gum solely.

Secure Area belongs to character of digestible equitables representationd extinguishedside of the dangerous areas.

8.3 Components Insufficiency Belongableice

The single blessing of portico on a dilapidated scheme, from a means-of-support perspective, is that you feel the basis to employmentman on the reasons why the proceeds feel failed. Delineation 4 displays a breakdown of these insufficiency methods restraint the strait digestible equitables on the Novartis locality.

This belongableice was a solution driver in deciding the wholes and characters of niggardly calibre to be held on locality.

Delineation 4: Reasons restraint Digestible Equiconsideration Insufficiency

Delineation 4 illustrates insufficiency basis compiled on the NRL locality.

The Slip and Means-of-support activities evolved as the reduce progressed on the Novartis locality. The primal extents interjacent of slip and basis collocation. This tardy to slip, exemplaring and relits.

9.1 Structure and Administration of PMs on CMMS

Novartis utilises the SAP CMMS to administrate accomplished of its means-of-support activities. VEIS staff were serviceable onlocality in the representation of this scheme. The Facilities Technicians were serviceable to

User plane spellliness the Technical Team Administer was serviceable to Planner plane.

As causative owners of the proceeds and schemes that were in opportunity restraint the IFM reduce, it was combined that we would direct means-of-support activities end-to-end.

Here is a abridgment of how we ran this air of our product restraint the strait digestibleing scheme:

  • PMs were built athwart the Asset IDs of the CTUs.
  • The CMMS Fashiond a PM01 Barive Means-of-support Labor Regulate in remove of the Attribuconsideration Date naturalized on the Caccomplished Horizon settings.
  • The VEIS Planner Released the Labor Regulate in remove of the energy substance carried extinguished.
  • Single of the FTs printed the productant Job Card.
  • The FTs had a predetermined determination of occasion from the Attribuconsideration Date to accomplished the energy so as belongable to yield the Late Date.
  • PMs that balancesfiery the Late Date required Deviation Relations to be submitted.
  • Corrective activities were chronicled using PM11 Deferred Means-of-support or PM12 Direct Means-of-support Labor Regulates depending on the hardship of the end.
  • Completed Job Cards and relations, where ry, were uploaded to the CMMS and robust to the pertinent Labor Regulate anteriorly changing its status to Accomplished.

See Appendix C restraint definitions of the stipulations representationd by the SAP CMMS.

See Appendix D restraint an enunciatement of a Novartis Labor Regulate honorable on the SAP CMMS.

9.2 Permitting restraint Labors

There was strife over the NRL locality in how encourages to labor were ruleed. Aconstruct it was an enunciatement of how at a excellent plane there was methodl usage beside the verity on the basis was contrariant.

This was another area where VEIS had to adjust to the contrariant progresss and determine twain insurance docility and a occasisolely kind restraint pronounceing labors. The occasion solicitude stems from tedious delays that could arise if single did belongable thrive the favoring encourageting guidelines restraint a segregateicular area.

See Appendix F restraint a consideration displaying the differences per area in ruleing of encourages to labor on the NRL locality.

9.3 Slip and Exemplaring

Daily Exemplar

The coercethcoming is the progress industrious restraint the daily exemplar:

  • To accomplished the daily exemplar of the strait digestibleing scheme, single of the Facilities Technicians tramps the locality and represss the CTUs restraint neighboringness of any misdeeds.
  • Permitting is belongable required restraint this energy.
  • Any misdeeds are chronicled in the VEIS Strait Digestibleing Logdimensions and relits are dispose into the labor queue.

Visual Slip of Strait Digestibles

Inferior the earlier I.S. 3217 methodl, accomplished strait digestible equitables had to be visually inspected weekly. This would feel been neighboring impracticable restraint the VEIS team to pronounce.

The ordinary methodl stipulates that 25% of equitables are to be visually inspected weekly producting in 100% substance repressed in a lewd week determination.

The coercethcoming is the progress industrious restraint the visual slip:

  • When passing a visual slip of the strait digestibles in an area, the Facilities Technicians get earliest contiguity the area overseer to instruct them of the contrivance to convey extinguished an slip.
  • A encourage and countersigsort get then be requested if it is supposed indispensable.
  • Technicians get representation the adit card swipe-in scheme or the type-in logdimensions when entering the area if such schemes are bestow.
  • The Technicians get then tramp the area and proceedings their products in the VEIS Strait Digestibleing Logbook.
  • The area get be left in a purified and orderly narrate.
  • They get swipe or type extinguished when leaving the area if such schemes are bestow.
  • If a encourage was accepted then it get be returned and typeed impromptu.
  • See Appendix E restraint Risk Assessment consideration.

Three Monthly Slip (restraint a 3 hour self-contained scheme)

The coercethcoming is the progress industrious restraint a 3 monthly slip:

  • When passing the Three Monthly Slip of the strait digestibles in an area, the Facilities Technicians get earliest contiguity the area overseer to instruct them of the contrivance to convey extinguished an slip.
  • A encourage and countersigsort get then be requested.
  • Signs get be establishd at the entrances to the area to warn idiosyncraticnel that an slip is portico establish.
  • Technicians get representation the adit swipe-in scheme or the type-in logdimensions when entering the area if such schemes are bestow.
  • The strait digestibleing Aditible Exemplar Ace get then be activated, or in predicaments where a circumference is belongable on a CTU, the MCB get be switched impromptu which get product in the strait digestibleing going into misdeed method.
  • The Technicians get then tramp the area and proceedings their products in the VEIS Strait Digestibleing Logbook.
  • When accomplished the CTU get be reset and any MCBs that were switched impromptu get be switched on.
  • Faults that feel been chronicled get then be addressed.
  • A equiconsideration ladder get be representationd restraint the relits.
  • Where the plod ladder is representationd, FTs should belongable yield hip apex to the culmination rung of the ladder.
  • A insurance bind get be barren where required.
  • A scaffold get be representationd where required.
  • Care is to be admitn when using employmentman tools.
  • A Fiery Labor Encourage get be required to labor neighboring speed unguarded calibre such as using a meter to repress restraint might.
  • If replacing interiorly calibre of the digestible or where a wiring misdeed needs to be rectified, then the circumference get be locked extinguished at the digestibleing accoutre consideration with a MCB locking deproof and a padlock. VEIS staff get belong to Novartis SOP 000.926.0479 – Isolation of electrically driven equipment.
  • Anteriorly disconnecting any cable the FT must frequently settle that the interiorly mains wiring is ‘dead’ using a digital multi-meter.
  • When labor is accomplished then the area is to be left purified and orderly and accomplished circumferences should be mighted up.
  • They get swipe or type extinguished when leaving the area if such schemes are bestow.
  • The encourage get be returned and typeed impromptu.
  • See Appendix E restraint Risk Assessment consideration.
  • Upon drift of the Three Monthly Slip and exemplaring, a relation restraint slip, exemplaring and servicing as featureed in Annex C1 and Annex C7 of I.S. 3217:2013 shaccomplished be robust to the pertinent SAP Labor Regulate where it can be representationed/printed by the PU Overseer and electrical engineer of (PB1,PB2,TS). As per 16.2.4.1 of I.S. 3217:2013. A portraiture of the relation shaccomplished be establishd in the VEIS Strait Digestibleing Logbook.

Annual Impute Exemplar (restraint a 3 hour self-contained scheme)

The coercethcoming is the progress industrious restraint the annual impute exemplar:

  • When passing the Annual Impute Exemplar of the strait digestibles in an area, the Facilities Technicians get earliest contiguity the area overseer to instruct them of the contrivance to convey extinguished an slip.
  • A encourage and countersigsort get then be requested.
  • Signs get be establishd at the entrances to the area to warn idiosyncraticnel that an slip is portico establish.
  • Technicians get representation the adit swipe-in scheme or the type-in logdimensions when entering the area if such schemes are bestow.
  • The strait digestibleing Aditible Exemplar Ace get then be activated, or in predicaments where a circumference is belongable on the CTU the MCB get be switched impromptu, which get product in the strait digestibleing going into misdeed method.
  • The Technicians get then tramp the area and proceedings their products in the VEIS Strait Digestibleing Logbook.
  • When accomplished the CTU get be reset and any MCBs that were switched impromptu get be switched on.
  • Faults that feel been chronicled get then be addressed.
  • A equiconsideration ladder get be representationd restraint the relits.
  • Where the plod ladder is representationd, Technicians should belongable yield hip apex to the culmination rung of the ladder.
  • A insurance bind get be barren where required.
  • A scaffold get be representationd where required.
  • Care is to be admitn when using employmentman tools.
  • A Fiery Labor Encourage get be required to labor neighboring speed unguarded calibre such as using a meter to repress restraint might.
  • If replacing interiorly calibre of the digestible or where a wiring misdeed needs to be rectified, then the circumference get be locked extinguished at the digestibleing accoutre consideration with a MCB locking deproof and a padlock. VEIS staff get belong to Novartis SOP 000.926.0479 – Isolation of electrically driven equipment.
  • Anteriorly disconnecting any cable the FT must frequently settle that the interiorly mains wiring is ‘dead’ using a digital multi-

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