1. PURPOSE: To define the procedure for control over the use of compressed air.

2. SCOPE: Production

3. RESPONSIBILITY: In charge of Production

4. PROCEDURE:

Sr. No	ACTIVITY	RESPONSIBILITY
01	Ensure proper condition of air circulation piping system during preventive maintenance.	In charge Maintenance
02	Ensure no leakage of compressed air oil piping system in the shop.	Operator/supervisor.
03	In case of air leakage, inform maintenance to rectify the same.	Operator/supervisor.

5. CHECKING, CORRECTIVE AND PREVENTIVE ACTION:

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

1.PURPOSE:   To provide the guideline for Disposal of Garden tools

2.SCOPE:  This is applicable for Admin

3.RESPONSIBILITY: Admin in charge is responsible for the implementation of this OCP

4. INSTRUCTIONS:

• After completion of work, collect all used tools Check the tool condition for damage, etc
• If found damage, do rework and use
• If rework is not possible, dispose to scrap yard
• Ensure the use of proper PPE’s during disposal

5. CHECKING, CORRECTIVE AND PREVENTIVE ACTION:

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

1.PURPOSE:

To instruct & to ensure the care to be taken related to Environment, OHSAS by Admin Dept

2. SCOPE:

This is applicable to canteen contractor and other agency who looks after all canteen activities like getting hygienic good food from outside, serving, cleaning of utensils & canteen area for the employees of the company, in all shifts.

3. RESPONSIBILITY: HOD Admin is responsible for this work instruction.

4. INSTRUCTIONS:

1. The wastewater from the bathrooms and toilets are to be properly drained.
2. In no case the soak pit to be made near the underground tube well or the open well.
3. The bathrooms and toilets are cleaned every day.
4. The toilets must have proper ventilation systems.
5. There should be adequate ladies toilet for lady employees.
6. The drinking water is to be treated before use.

5. RECORD REF.: Six Monthly Audit Record by HOD Admin. Drinking water analysis report every six month

1.PURPOSE: To provide the guideline for control & monitor the consumption of electricity

2. SCOPE: This is applicable for the consumption of electricity for Total lighting load

3. RESPONSIBILITY:    HOD Admin

4. INSTRUCTIONS:

Daily readings under office area, canteen area, Training area, security area are reviewed & if found abnormal, then immediate corrective actions are taken by HOD Admin. After reviewing the collected data, HOD Admin analyses per product electricity consumption on a monthly basis. Abnormal trends are further analyzed for corrective actions & control measures suitable to the area.

CONTROL METHODOLOGY:

Electrical consumption is controlled by the following methods:

• Awareness training amongst the employees.
• By Brainstorming in the user groups
• By promoting different ideas from employees regarding energy conservation
• Display boards like “Save Energy”, “Switch-off lights & fans before leaving the place”, “Switch-off cooling tower & compressor in lunch & dinner time”.
• Daily monitoring of electricity consumption units by all In charge of HR.

 MONITORING AND COMPARISON

New consumption levels are assessed by the HOD MNT and the results are compared with targets. The successful solutions are continued whereas unsatisfactory solutions are reviewed for improvements

5. OPERATIONAL CONTROL:

Sr. No	The parameter to be Monitored	Spec	Frequency	Method	Responsibility	Record
1	Review of Consumption at an office area, canteen area, security area, and training hall	Ideal Power Factor	Monthly	Daily Consumption Record	HOD MNT	Review Record

6. RECORD REF: Electrical consumption records in various areas.

1.PURPOSE: To minimize the accidents while operating the machines

2.SCOPE: This  is applicable to the whole plant

3.RESPONSIBILITY:  Departmental HOD’s

4. INSTRUCTIONS:

• Responsibility: Operator/Supervisor
• Safety Precautions to be taken while using Compressed Air
• Ensure proper training is given to operator on machine operation as well as its emergency switches
• Ensure PPE list is available on each line and check its condition.
• Ensure proper condition of hand tools.
• Display list of Fire Fighting team who are trained on safety, fire fighting & first aid.
• Ensure easy availability of First Aid Box with medicine list.
• No operator shall work without safety shoes.
• Ensure that all valves are shut during non-use period and are secured to the port correctly with no gap.
• Ensure conveyor crossing by using the cross-over ladder only.
• No blade or sharp knife should be used without a proper & safe grip.

5. RELATED RECORDS: Accident and Incident record

1.PURPOSE: To minimize the use of water

2.SCOPE: This WI is applicable to the whole plant

 3. RESPONSIBILITY: Departmental HOD’s

4.INSTRUCTIONS:

1. Use of water should be monitored by using water meter at appropriate places
2. Wherever possible, posters such as Save water, Don’t Waste Water, etc to be displayed
3. Damaged pipes, taps, coolers should be replaced immediately
4. Leakages, spillages should be avoided
5. Periodic preventive maintenance should be done
6. In operational processes wherever possible water should be recycled
7. Water from STP, ETP should be used for gardening purpose

5.RELATED RECORDS: Water measurement records

1.PURPOSE: To minimize health risks by controlling  the heat generation

2.SCOPE: This WI is applicable to Production, QA, Tool Room, and Housekeeping

3. RESPONSIBILITY: Departmental HOD’s

4. INSTRUCTIONS:

1. Ensure that all operators working under the heat generating area are using the mask
2. Monitoring of heat generation to be done periodically
3. Where possible, the heat extraction system should be installed
4. Periodic preventive maintenance should be done
5. Operators working under heat generating area should be monitored for health
6. Ensure that proper blowers/fans are in place
7. Adequate clothing to be provided to the operators

5. RELATED RECORDS: Temperature monitoring record

1, PURPOSE: To minimize health risks by controlling dust, fumes generation

2. SCOPE: This is applicable to Production, QA, Tool Room, and Housekeeping

3. RESPONSIBILITY:       Departmental HOD’s

4. INSTRUCTIONS:

1. Ensure that all operators working under dust/fumes generating area are using the mask
2. Monitoring of dust/fumes generation to be done periodically
3. Where possible, dust/fume extraction system should be installed
4. Periodic preventive maintenance should be done
5. Operators working under dust/fumes generating area should be monitored for health

 5. RELATED RECORDS:     Monitoring Records

1.PURPOSE: To control the generation of noise

2. SCOPE: This work instruction is applicable to all departments

3.0 RESPONSIBILITY:  Departmental HOD

4. INSTRUCTIONS:

1. Conduct a survey to know noise generating areas/machines/ Operations.
2. Analyze Survey report and prepare an action plan to reduce noise level wherever possible.
3. Take necessary measures as per the action plan to reduce the noise level.
4. Review the action plan for the effectiveness of the actions taken.
5. Controlling the noise at the source, through a process of elimination or engineering measures, can be done in a variety of ways and is often easier in the long term than a personal protective equipment program.  Rethinking how a task can be done can greatly reduce the amount of noise it generates.  For example, bending a strip of metal using a hammer generates a great deal of noise; changing techniques to bending it with a vice and pair of pliers is a much quieter alternative.
6. Some effective and practical methods for reducing the amount of noise employees are exposed to include:
   • installing springs and rubber strips to reducing the amount of vibration and resonance of the equipment;
   • enclosing noisy equipment with noise absorbing/reflecting material;
   • moving the source of noise away from where people work; and
   • purchasing quieter equipment.
   • Additionally, well-serviced equipment is often quieter, so ensuring that equipment is in good working order will reduce noise exposure.
7. Administration controls, while not as good as eliminating noise at the source, are also effective ways of reducing noise exposure. They include:
   • training;
   • signage;
   • limiting duration of exposure via work rotations; and
   • having ‘no-go’ areas.
8. Personal protective equipment can be used if all other controls do not reduce the noise levels to an acceptable level. The appropriate level of hearing protection to be used must correspond with the level of noise exposure.

5.RELATED RECORDS:

Noise monitoring records

1. PURPOSE:

To identify, storage, handling, segregation, and disposal methods of all types of waste.

2. SCOPE:

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

3. RESPONSIBILITY:

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

4. INSTRUCTIONS:

1. Wastes generated from different operations are stored either in plastic drums, gunny bags or any other identified bins at the waste generation points.
2. The waste collected at various points as described above are shifted to scrap yard / identified the place, either manually or with the help of trolley/forklift truck.
3. Ensure that there is no spillage of scrap/waste during collecting and shifting of scrap/waste to the scrap yard.
4. The 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, Use spare parts and used PPE’s	Stored in the scrap yard	Manual	Disposed to the scrap vendor	HOD-SAFETY/HOD -PUR
2.	Waste paper, cotton waste,  hand gloves	Stored in the scrap yard	Manual	Disposed to the scrap vendor	HOD PRD & HOD PUR
3.	Wooden & plastic packing waste	Stored in the scrap yard	Manual	Disposed to the scrap vendor	HOD PUR
4.	Polythene bags, plastic waste, boxes	Stored in the scrap yard	Manual	Disposed to the scrap vendor	HOD PUR

5. 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.

5.  INSTRUCTION FOR SUPERVISION OF SCRAP LOADING:

a) Arrange to record the weight of the empty truck.
b) Allow the truck to scrap area and supervise the loading of the scrap material
c) Ensure that no other scrap material other than the scrap is loaded on to the truck.
d) Record all relevant details of scrap & inform accordingly to Accounts Dept.
e) While loading the scrap, contractual personnel should take safety measures such as – should wear hand gloves.

6. OPERATIONAL CONTROL: 

Sr.No	The parameter to be Monitored	Spec.	Freq. of monitoring	Method of monitoring	Responsibility	Record
1	Mix up the various waste	No mix-ups.	Daily	Visual check & display boards.	HOD HRD	No Record
2	Quantity of scrap disposed of.	–	While disposing	–	HOD HRD.	Invoice

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