Author: Pretesh Biswas

Pretesh Biswas has wealth of qualifications and experience in providing results-oriented solutions for your system development, training or auditing needs. He has helped dozens of organizations in implementing effective management systems to a number of standards. He provide a unique blend of specialized knowledge, experience, tools and interactive skills to help you develop systems that not only get certified, but also contribute to the bottom line. He has taught literally hundreds of students over the past 5 years. He has experience in training at hundreds of organizations in several industry sectors. His training is unique in that which can be customized as to your management system and activities and deliver them at your facility. This greatly accelerates the learning curve and application of the knowledge acquired. He is now ex-Certification body lead auditor now working as consultancy auditor. He has performed hundreds of audits in several industry sectors. As consultancy auditor, he not just report findings, but provide value-added service in recommending appropriate solutions. Experience Consultancy: He has helped over 100 clients in a wide variety of industries achieve ISO 9001,14001,27001,20000, OHSAS 18001 and TS 16949 certification. Industries include automotive, metal stamping and screw machine, fabrication, machining, assembly, Forging electrostatic and chrome plating, heat-treating, coatings, glass, plastic and rubber products, electrical and electronic equipment, assemblies & components, batteries, computer hardware and software, printing, placement and Security help, warehousing and distribution, repair facilities, consumer credit counseling agencies, banks, call centers, etc. Training: He has delivered public and on-site quality management training to over 1000 students. Courses include ISO/TS -RAB approved Lead Auditor, Internal Auditing, Implementation, Documentation, as well as customized ISO/TS courses, PPAP, FMEA, APQP and Control Plans. Auditing: He has conducted over 100 third party registration and surveillance audits and dozens of gap, internal and pre-assessment audits to ISO/QS/TS Standards, in the manufacturing and service sectors. Other services: He has provided business planning, restructuring, asset management, systems and process streamlining services to a variety of manufacturing and service clients such as printing, plastics, automotive, transportation and custom brokerage, warehousing and distribution, electrical and electronics, trading, equipment leasing, etc. Education & professional certification: Pretesh Biswas has held IRCA certified Lead Auditor for ISO 9001,14001 and 27001. He holds a Bachelor of Engineering degree in Mechanical Engineering and is a MBA in Systems and Marketing. Prior to becoming a business consultant 6 years ago, he has worked in several portfolios such as Marketing, operations, production, Quality and customer care. He is also certified in Six Sigma Black belt .

OCP for Storage and Disposal of Metallic Waste and Garbage

1. PURPOSE:

a) To store metallic chip/waste and garbage received from factory premises.
b) To dispose of the waste safely.
c) To store and dispose of lead-acid batteries.

2. SCOPE: Scrapyard

3. RESPONSIBILITY: In charge Stores / Sr.Officer HRD

4. PROCEDURE:

Sr.No	ACTIVITY	RESPONSIBILITY
01	Communicate the guideline to service contractor to follow environment-friendly practices.	In charge Stores
02	Provide adequate material handling equipment to the contractor.	Sr. Officer-Admin
03	Impart training of environment-friendly practices to housekeeping operator.	Sr.officer Admin / Housekeeping contractor
04	a) Collection of chips/waste/ garbage from various locations by using the trolley. b) Ensure that there is no spillage of chips/oil/ garbage during collection and transportation. c) Ensure that trolley does not get overflow because of excess collection. d) Ensure that good quality material is not present in collected material (scrap).	Housekeeping operator
05	Transport the metallic chips/garbage to scrap yard. During transportation ensure that there is no leakage of chips from the trolley. Avoid land contamination.	Housekeeping operator
06	Communicate guideline on environment-friendly practices to the transporter.	In charge Stores
07	Invite/inform the contractor for collection of metallic waste/garbage.	In charge Stores
08	At the time of loading of metallic chips/garbage into the truck, avoid spillage.	Transport contractor / Security guard
09	Supervise the collection activity and report the weight of the vehicle (metallic waste collected) to the Materials department.	Security guard
10	Store the scrapped lead-acid batteries on the wooden platform in the scrap yard.	Housekeeping operator
11	At the time of procurement of new batteries, handover the batteries to dealer/subcontractor and get the replacement against the old batteries.	In charge Stores

5. CHECKING, CORRECTIVE AND PREVENTIVE ACTION:

In case of any deviation in the above activity, In charge Materials shall initiate appropriate corrective and preventive action.

6. RELATED DOCUMENTS:

• Guideline for contractors.

7. Related Records

Name of record	Indexing On	Retention Period	Maintained by
Records of metallic waste generated/ sold in a month	Date	3 years	In charge Stores
Records of garbage generated/sold in a month	Date	3 years	In charge Stores

OCP of Handling, Transportation, and Disposal of Hazardous Waste

PURPOSE:

To aware & know handling and disposal methods of hazardous waste.

SCOPE:

This work instruction is applicable to hazardous wastes generated at all process, activities, and services at XXX

RESPONSIBILITY:

HOD will ensure that contractors and scrap vendors practice these work instructions.

INSTRUCTIONS:
1. Hazardous wastes generated from different operations are stored in identified bins at the waste generation points.
2. The hazardous waste collected at various points as described above is shifted to scrap yard / identified place manually.
3. Ensure that there is no spillage of scrap/waste during collecting and shifting of scrap/waste to the scrap yard.
4. The hazardous waste/scrap generated at various points, method of storage, handling, and disposal along with personnel responsible are as detailed below:

Sr.No	DESCRIPTION	STORAGE	HANDLING	DISPOSAL	RESP.
1.	Empty barrels of OIL, grease, Paint, Chemicals used etc.	Stored in the scrap yard	Manual	Disposed to the authorized scrap vendor	HOD PUR
2.	Oil socked sawdust, oil socked cotton waste, oil socked metal scales	Stored in the scrap yard	Manual	Disposed to the authorized vendor	HOD PUR
3.	Metal waste, broken m/c parts, used & broken wheels etc.	Stored in the scrap yard	Manually by using hand gloves	Disposed to the scrap vendor	HOD PUR
4.	Waste oil mixed with water	Stored in barrels	Manually, forklift use while transporting	Disposed to the authorized vendor	HOD MAINT/ HOD PUR
5.	Waste oil (hydraulic and lubrication oil	Stored in barrels	Manually using rubber gloves	Disposed to the authorized vendor	HOD MAINT/ HOD PUR
6.	Scraped Batteries	Stored in the Maint.Store	Manual	Disposed to the authorized scrap vendor	HOD MNT
7.	E-waste	Stored in the scrap yard	Manually by using hand gloves	Disposed to the scrap vendor	HOD PUR
8.	STP Sludge	Stored in pits	Manually with hand gloves	In-house disposal for gardening activity	HOD/ HRD
9.	ETP sludge	Closed concrete pit	Manually by using hand gloves & plastic bins	To be Disposed of to the authorized vendor	HOD/HRDProspecting department

Concerned department in charges will ensure on a daily basis there is no mix up of scrap/waste during collection & storage. In case of such mix-up, he will arrange for segregation. He also should ensure that while handling any type of scrap there should not be any spillover on the ground.
The Collected Hazardous waste will be disposed of in Eco-friendly manner with Maharashtra Enviro Power Ltd and all the requisites will be followed as per Hazardous Waste (Management & Handling) Rules 2008, while disposing of the Hazardous Waste Material.
Ensure the availability of fire extinguishers near the storage of Hazardous waste.

5.OPERATIONAL CONTROL:

Sr. No	The parameter to be Monitored	Spec.	Freq.of Monitoring	Method of monitoring	Resp.	Record
1	Disposition Empty drums	Disposal to the authorized dealer	Monthly	Record of Qty. shifted to scrap yard	HOD STR	Record sheet
2	Disposal of – a) Waste oil. b) Scraped Batteries	Disposal to the authorized dealer	Each disposal	Record of Qty. being disposed of.	HOD STR	Record of Qty. disposed.
3	Disposal of ETP sludge	Disposal to MEPL/ authorized dealer	Each disposal	Record of sludge generation	HOD HR	Record of Qty. disposed

6.0 RECORD REF.: Report / Invoice on waste/scrap sold

OCP for Handling And Disposal of Waste Oil

1. PURPOSE: To collect, store and dispose of waste oil.

2. SCOPE: Scrapyard

3. RESPONSIBILITY: In charge Stores / HOD HRD/ In charge Purchase.

4. PROCEDURE:

Sr.No	ACTIVITY	RESPONSIBILITY
01	Sale Waste oil to government approved/authorized contractors only and Communicate the guideline to service contractor to follow environment-friendly practices.	In charge Purchase
02	Provide adequate material handling equipment to the contractor.	Sr. Officer HRD
03	Impart training of environment-friendly practices to housekeeping operator.	Sr.officer (HRD) / Housekeeping contractor
04	a) Collection of waste oil from the shop floor. b) Ensure that there is no spillage of oil during collection and transportation. c) Ensure that a barrel of oil does not get overflow because of excess collection.	Housekeeping operator
05	Communicate guideline on environment-friendly practices to the transporter.	In charge purchase
06	Invite/inform the contractor for collection of waste oil.	In charge purchase
07	At the time of loading of waste oil barrel into the truck, ensure no spillage.	Transport contractor / Security guard
08	At the time of sale of empty oil/chemical barrels to employees/contractors, communicate the guidelines to them about safe usage of empty barrels.	Safety Officer
09	Maintain the records of hazardous waste sold to subcontractors of hazardous waste manifest	Safety Officer
10	Get the acknowledgment of the manifest from the subcontractor	Safety Officer

5. CHECKING, CORRECTIVE AND PREVENTIVE ACTION:

In case of any deviation in the above activity, in charge purchase shall initiate appropriate corrective and preventive action.

6. RELATED DOCUMENTS:

• Guideline for the contractor to follow environment-friendly practices.
• Guidelines for safe usage of empty chemical/oil barrels.

OCP for Handling, Storage, and Distribution of Diesel/ Furnace Oil

1. PURPOSE: To define the procedure for handling, storage, and distribution of FO/furnace oil/diesel.

2. SCOPE: Stores

3. RESPONSIBILITY: Section In-charge Stores

4. PROCEDURE:

Sr. No.	Activity	Responsibility
1	During unloading of furnace oil / FO from the tanker, ensure no leakage/spillage. No unloading of diesel or FO during nighttime.	Supervisor
2	Before unloading, clamp the hose properly.	Truck Driver/Supervisor
3	During the transfer of oil / FO to the service tank, ensure no leakage/spillage from the supply pump – pipeline – joints – valves.	Supervisor/Operator
4	Ensure that the pump is switched off before overflowing from the service tank.	Operator
5	Furnace oil / FO/Hydraulic oil storage area is a prohibited area. Do not allow smoke /light/fire in the zone.	Supervisor/Operator
6	In case of any fire hazard, take appropriate corrective actions. Refer procedure for fire fighting, manual of fire fighting.	Supervisor/Operator
7	Obtain a license for the storage of petroleum products from the regulatory authorities.	Section In charge.
8	Arrange to check of periodic integrity of the FO storage (underground) tank from the chartered engineer. Frequency – once in 5 years. Maintain the records of checking.	Section In charge.

5. CHECKING, CORRECTIVE AND PREVENTIVE ACTION:

Section In-charge Stores shall ensure implementation of the above procedure. In case of any deviation, initiate corrective and preventive action.

6. RELATED DOCUMENTS:

The license of storage of petroleum products under Petroleum act 1976 rule 140 (Petroleum class C)

7. RELATED RECORDS:

Records of periodic checking Of FO, Furnace oil, Storage tank

OCP for Handling and Disposal of Grinding Dust

1. SCOPE: Machine shop / Scrapyard

2. RESPONSIBILITY: Sr.Officer Admin

3. PROCEDURE:

Sr.No	Activity	RESPONSIBILITY
01	Communicate the guideline to service contractor to follow environment-friendly practices.	HOD Admin
02	Provide adequate material handling equipment to the contractor.	Sr Officer Admin
03	Impart training of environment-friendly practices to housekeeping operator.	Sr.officer (HRD) / Housekeeping contractor
04	a) Collect the grinding dust from the Machine shop. b) Ensure that there is no spillage of grinding dust during collection and transportation. c) Ensure that trolley of dust does not get overflow because of excess collection.	Housekeeping contractor
05	Transfer the grinding dust to the identified location and dispose of the same.	Housekeeping contractor

4. CHECKING, CORRECTIVE AND PREVENTIVE ACTION:

In case of any deviation in the above activity, HOD HRD shall initiate appropriate corrective and preventive action.

5. RELATED DOCUMENTS:

Guideline for contractor

OCP for the Collection, Transportation, and Disposal of Garbage

1.PURPOSE

a) To collect paper boxes / corrugated boxes, polythene bags, etc from all factory area.
b) To transport the garbage to scrap yard area
c) To dispose of the garbage

2. SCOPE:

XXX plant operation

3. RESPONSIBILITY:

HOD Admin

4. PROCEDURE:

Sr.No.	Activity	Responsibility
1	Communicate the guidelines to the service contractor to follow environment-friendly practices:- – Provide adequate material handling equipment to the contractor. – Impart training on environment-friendly practices to housekeeping operator.	HOD Admin. Housekeeping contractor
2	Collect paper box/corrugated box, polythene bags, etc from all factory area.	Housekeeping Contractor
3	Ensure that there is no spillage of garbage during collection and transportation.	Housekeeping Contractor
4	a) Ensure that trolley does not get overflow because of the excess collection of garbage. b) Transport the garbage to scrap yard for further disposal. During transportation, ensure that there is no leakage /spillage of garbage from the trolley. c) At the time of sale of garbage, ensure proper collection of garbage i.e. no spillage. d) Supervise the collection activity and report the weight of the vehicle (garbage collected) to the Materials department. e) Communicate guidelines on environment-friendly practices to garbage contractor/transporter. f) Invite /inform the contractor for collection of garbage. g) Ensure that proper housekeeping is maintained in the scrap yard.	Housekeeping Contractor

5. Checking, Corrective and Preventive Action.

In case of any deviation in the above activity, Sr.Officer (Admin) shall initiate appropriate corrective and preventive action.

6. Related Documents

Guidelines for contractor /Transporter.

OCP for Transporters and Vehicle Owners

1.PURPOSE:

To instruct & to ensure the care to be taken related to Environment and Occupational Health & Safety by transporters & other vehicle owners.

2. SCOPE:

This work instruction is applicable to all vehicles belongs to Transporters, Employees, XXX owned and visitors, etc. and for the vehicle stationed at the company premises.

3. RESPONSIBILITY:

HOD – Admin is responsible for ensuring that all the above-mentioned vehicle owners and transporters adhere to this work instruction.

4.INSTRUCTIONS:

4.1 BASIC REQUIREMENTS:
HOD – Admin ensures the following

Every employee vehicle has valid PUC certificate.
Regular transporter should submit a copy of valid PUC certificates
Regular transporter should submit a copy of valid licenses/permits etc.
Others should have a valid PUC certificate for their vehicles & driving license.
Driver for company vehicles should also have valid PUC certificate and Licenses.
Finished goods transported to be covered under insurance.
All company vehicles to have R.C. /T.C. Book.
Ensure periodically servicing to ensure there is no oil leakage for regular visiting vehicles.

4.2 SAFETY INSTRUCTIONS:

All employees riding on two-wheelers should wear safety helmets while driving.
All drivers & employees should strictly adhere to traffic rules.

5.OPERATIONAL CONTROL PLAN :

Sr. No	The parameter to be Monitored	Spec.	Freq. Of monitoring	Method of monitoring	Resp.	Record
1	Vehicles entering plant premises are Non-pollute.	Pollution under control	Monthly	Valid PUC Certificate.	HOD – Admin	Register for monitoring PUC certificate
2	Periodical review for oil leakage	No oil leakage	Three Month	Manual	HOD – Admin	No Record

6. RECORD REF.: Register for monitoring PUC certificate.

OCP for Housekeeping and Air Quality Monitoring

1.PURPOSE:

To instruct & ensure the care to be taken to provide good housekeeping and Air Quality Monitoring at the entire premises of XXX.

2. SCOPE:

These work instructions are applicable for carrying out housekeeping and Air Quality Monitoring activities at XXX

3. RESPONSIBILITY:

HOD Amin is responsible for ensuring that the housekeeping contractor will practice this work instruction.

4. INSTRUCTIONS :

HOD Admin ensures:

Instruct contractor to employ the sufficient number of persons for covering all the areas viz. shop floor, offices, utilities, toilets, & garden.
Availability of sufficient no. of mops, cleaning soap, other toiletries with the contractor.
All areas are free from cobwebs & dust.

4.1 SAFETY INSTRUCTIONS:

HOD Admin ensures the following:

All contractual personnel wears their safety shoes, other PPEs, and proper uniform while working.
While using a ladder or cleaning the places above six feet/ sufficient care is to be taken i.e. two persons stand below, holding the ladder when one person is working at height on the ladder. Person climbing high is supposed to use safety belt.
Stacking of material in the scrap yard up to the safety mark or wall height.
Usage of hand gloves by contractual personnel while handling burr or any other hazardous wastes.
Use of disinfectants like phenyl in the office area for proper hygiene.

4.2 WORK INSTRUCTIONS:

Carry out housekeeping of various areas as per the frequencies mentioned in the chart below

Area	Type of Cleaning	Cleaning Frequency
Utility area, stores, Security room, Office blocks, shop floor	Sweeping	Daily
Departmental office, reception	Sweeping	Daily
toilets	Mopping with phenyl	Daily
Portable water storage tanks	Mopping after emptying	Once in a month
Shop floor lights	Sweeping / Cleaning	Once in a month
Water cooler	Emptying & cleaning with soap	Once in a month
A whole company ( for insects, pest)	Spraying of pesticides	Once in six months
Garden	Cutting, trimming & housekeeping	As & when instructed by a consultant
Toilet	Cleaning of blower	Monthly

After cleaning the floor with soap water, collect the scrubbed water with vacuum cleaner & let out this water to drain line which in turn goes to outside channel.
After mopping & sweeping up the area, all contractors should follow the work instruction for Segregation & disposal of solid waste.

5.0 OPERATIONAL CONTROL PLAN:

Sr.No	The parameter to be Monitored	Spec.	Freq.Of Monitoring	Method of monitoring	Resp.	Record
1	Ambient Air Quality	SO2-80µg/m³ SPM-100µg/m³ Nox-80µg/m³ RSPM- 60µg/m³	Once in a six months	External Lab	HOD HRD	Report form External Agency Stored in safety dept.
2	Work zone Air Quality	SO2-5 mg/m³ NOx-TWA 6 mg/m³ CO-55mg/m³	Once in a six months	External Lab	HOD HRD	Report form External Agency Stored in safety dept
3	Ambient Noise Level	Day time-75dBA max. Night time-70 dBA max.	Once in three months	External Lab	HOD Admin	Report form External Agency Stored in safety dept
4	Work Zone Noise level	90 db A max for eight hours	Once in three months	External Lab	HOD Admin	Report form External Agency

6.0 RECORD REF. : Reports from External Agencies.

OCP for Monitor and Maintain Fire Fighting Equipment and First aid kit

1.PURPOSE:

To instruct how to monitor & maintain fire fighting equipment and first aid kit.

2.SCOPE:

This work instruction is applicable to all fire extinguishers and first aid kits within the premises.

3. RESPONSIBILITY: HOD Admin

4. INSTRUCTIONS:

A. INSTRUCTIONS FOR CONTROL OF FIRE FIGHTING EQUIPMENT.

Arrange fire extinguisher in all plant area of a suitable type for each area.
Train employees to operate a fire extinguisher and maintain a record of same.
Audit fire extinguisher at the defined frequency and maintain the record.
Arrange mock drills & maintain the record of the same.
Inform concerned agency after use of fire extinguisher to replace it.

B. INSTRUCTIONS FOR MONITORING OF FIRST AID KIT:

Arrange first aid kit in the plant at all conspicuous places.
Train employees for using first aid & display list of trained persons on first aid kit.
Audit first aid boxes of each area monthly for checking availability of required medicines and maintain the record.

5. OPERATIONAL CONTROL PLAN:

Sr. No	The parameter to be Monitored	Spec.	Freq. Of monitoring	Method of monitoring	Resp.	Record
1	Fire extinguisher	OK condition	Monthly	Record	HOD Admin	Record of F.E.
2	First aid kit	Required medicines.	Monthly	Visual	HOD HRD	Record of audit

7.RECORD REF.: Maintenance record of fire extinguisher & first aid kit.

OCP for Mock Drill of Onsite Emergency Plan

1.PURPOSE:

To identify and take appropriate control measures to handle Accident and Emergency Situations.

2. SCOPE:

This Work Instruction is applicable for any sort of accident & emergency situation that emerges in the premises of XXX.

3. RESPONSIBILITY:

HOD Safety and concerned personnel are responsible for the implementation of the work instruction.

4. INSTRUCTIONS:

Incidents in the Following area are identified as the most potential emergency situations that can occur in our company.

Fire in

FO Storage tank
Welding stations
Surrounding Premises
DG Set
Transformer etc.
Oil Storage area
Laboratory

Plant Area including DG set / FO, Hydraulic oil Storage / Oil Storage

The person, who notices the fire will shout ‘Fire’, ‘Fire’ and ask for help and immediately informs the concerned person (*). The concerned person will start whistling to inform:

Trained fire-fighters to attend to the affected area
Evacuating the other personnel to the identified safe place.

The concerned HOD will ensure that nobody is trapped in the emergency area. The attempts will be made to evacuate the trapped person if any, using the safe way out. The HOD- Concerned department will take charge of the overall situation.
All the remaining employees will gather at a safe place outside.
the Concerned HOD or designate informs MD about the situation. the Concerned HOD also keeps him posted from time to time about the situation.
If the situation is out of control the HOD, where the event has happened will contact the local fire brigade.
The injured person if any, will be given first aid and moved to the nearest identified hospital.
The incident is recorded in the Register for Accidents and Emergency Situations by the Concerned HOD and analyzes it further.

ACCIDENTAL SITUATIONS OTHER THAN FIRE:

The person who is nearest to the injured person will call for help and arrange for first aid.
The injured person will be taken to the nearest first aid box in case it is possible or first aid is provided on the spot by a trained person available.
the Concerned HOD and MD are informed simultaneously by HOD HRD or designate.
Considering the severity of the injury, the injured person is shifted to the nearest hospital for further treatment. HOD HRD and/or concerned department in charge makes the required arrangement.
The incident is recorded in the Register for Accidents and Emergency situations by HOD HRD for further analysis. HOD HRD records the accident as required.
In case of an earthquake, all employees will immediately run out of the building in a safe area.

OPERATIONAL CONTROL PLAN:

Sr. No	The parameter to be Monitored	Specification	Frequency of Monitoring	Method of monitoring	Resp.	Record
1	Mock Drill.	No laps during Mock Drill	After every Mock Drill.Accident & emergency record	As per the Mock Drill record.	HOD HRD	Revision in On-Site Emergency Plan
2	Review of Onsite Emergency Plan.	Effective Emergency Plan.	After every accident & emergency situation	Accident & emergency Record.	HOD HRD	Accident & emergency record