Technological University of the Philippines
Ayala Boulevard, Ermita, Manila

COLLEGE OF LIBERAL ARTS
Bachelor of Arts in Management major in Industrial Management

IM 6
Plant Facilities and Safety Management

Name: Fernando J. Ronquillo Jr. / Matthew B. Orejola / Darren M. Marjes
Course, Year & Section: BAM-IM 3LE
Professor: Prof. Noel B. Hernandez
INTRODUCTION:
Description of Manual * The following safety policy is provided only as a guide to assist employers and employees, as well as to provide other helpful information. It is not intended to supersede the requirements of the standards. An employer should review the standards for particular requirements which are applicable to their individual situation and make adjustments to this program that are specific to their company. An employer will need to add information relevant to their particular facility in order to develop an effective, comprehensive program. It addresses not only the OSHA regulations and ways to reduce the exposure to hazards in your work areas, but also organizes a performance driven framework for continued focus and improvement on safety.

Maintenance of Manual
Distribution of Manual
Table of Organization
Functional Chart
Corporate Policy on Quality * Unilever’s mission is to meet everyday needs for nutrition, hygiene and personal care with brands that help people feel good, look good and get more out of life. And a key requirement is building in the quality expectations of our consumers into our products.
Corporate Safety Policy * Through our Vision Zero strategy – zero fatalities, zero injuries, zero motor vehicle accidents, zero process incidents, zero tolerance of unsafe behavior and practices – we aim to reduce risk not only to our employees but also to the wider community in which Unilever operates.

Corporate Policy on the Environment

* Unilever is committed to meeting the needs of customers and consumers in an environmentally sound and sustainable manner. We do this through continuous improvement in environmental performance in all our manufacturing activities worldwide

SAFETY PROCEDURES:

Safety and Health Committee

Personnel Safety Training
Safety Inspection
Maintenance of Fire Fighting Equipment
Hot Work Permit Issuance
Accident and Investigation Reporting * All injuries/illnesses must be reported to management as soon as possible. It is the policy of Unilever to have all injuries/illnesses investigated by Foremen or Assistant Foremen within 24 hours of incident. A formal Accident Investigation Form (available from the Safety Director) must be forwarded to the Safety Director as soon as possible. It is important that all incidents be reported, no matter how slight. Any property/liability loss claim must also be reported to management as soon as possible. The Safety Director will conduct a loss investigation of all property/liability claims.

Conduct of Fire and Evacuation Drill

Response To Emergency Calls

Personal Protective Equipment Issuance

Potable Water Analysis

Pest Control Activity

* A complete pest control management program MUST be in place and maximum attention must be given to prevent pest occurrence in food premises. * The site MUST have a nominated person responsible for pest control matters. Due to the specialist nature of pest control it is recommended that pest control be carried out by a professional third party company. In such cases the service contract MUST be clearly defined and reflect the activities of the site.

* Where a company manages their own pest control it MUST demonstrate the following;

* All pest control operations are undertaken by trained and competent staff with sufficient training to select appropriate pest control chemicals, application methods and understand the limitations of use, relevant to the pests associated with the site. * Demonstrate capability to respond to any infestation issues. * Have access to specialist technical knowledge when required * Understand local and end user legislation governing the use of pest control products. * Dedicated locked storage facilities for all pesticides * Details of pest control materials (poisons and fumigants) MUST be available to the Unilever to ensure they comply with Unilever requirements. * Any infected product MUST be completely segregated from other foods and destroyed. * The frequency of inspections MUST be determined by risk assessment and MUST be documented. * An up to date, signed and authorized bait plan MUST be in place. * ·Bait stations MUST be robust, of tamper resistant construction, secured in place and appropriately located to prevent contamination risk to product. * ·Fly killing devices and / or pheromone traps MUST be correctly sited and operational. If there is a danger of insects being expelled from any extermination device and contaminating the product, alternative systems and equipment MUST be used. * In the event of infestation, immediate action MUST be taken to eliminate the hazard. Action MUST be taken to identify, evaluate and authorize the release of any product potentially affected. * ·Detailed records of pest control inspections, recommendations and actions taken MUST be maintained. It MUST be the responsibility of the company to ensure all of the relevant recommendations made by their contractor or in-house expert are carried out and monitored. The completion of corrective action MUST be demonstrated by documented evidence. * Results of pest control inspections MUST be assessed and analysed for trends on a regular basis, but as a minimum: * in the event of an infestation * annually * This MUST include a catch analysis from trapping devices to identify problem areas. Any such problems MUST be suitably rectified.

Contractors Safety Guidlines

Operation of Fire Fighting Equipment
Design of Different Machine Guarding
Static Eliminator
Handling Compressed Gasses * Adequate ventilation MUST be provided to remove excessive heat, steam, and dust and to dry the area in an adequate time after wet cleaning (if used). * Where climate conditions like temperature or humidity are critical for product and/or material safety a control system MUST be in place with adequate capacity and be monitored. * Where the process requires screened or filtered air is in direct contact with the product, the equipment used for this purpose MUST be easily accessible and adequately maintained. Oil filters MUST be used on compressors unless the compressor is of the oil-free type. * Where appropriate, positive air pressure systems MUST be in place.

Handling Flammable Liquids
Contractors/Subcontractors Safety Meeting * SUBCONTRACTOR shall comply with the provisions of the Occupational Safety and Health Act of 1970, as amended, as well as all other applicable federal, state and local requirements. * A copy of SUBCONTRACTOR’S Safety Program, Hazard Communication Plan and Employee Acknowledgment of Hazard * Communication Training must be given to contractor prior to commencement of any work. Subcontractor is responsible for the safety of others, its employees, its sub-subcontractors, and equipment and property of others during the performance of its work and for any damage that might result from failure, improper construction, maintenance or operations. * contractor and their employees will adhere to all policies, procedures and requirements of Safety Program. Occupational Safety and Health Act of 1970, as amended, the more stringent requirements shall apply. * subcontractor and all employees shall follow all safety and jobsite rules promulgated by contractor. * During the performance of the work, subcontractor will take immediate action as required to correct and/or avoid any safety or hazard problem, violation or condition. * Subcontractor will immediately report all injuries and accidents to contractor’s Project Manager and submit a written report about each accident - on a contractor form - within twenty-four (24) hours. Subcontractor shall report all injuries and accidents to federal, state and local authorities and subcontractor’s insurance carrier as appropriate or required. * MSD sheets covering all materials and supplies to be used in the performance of the work will be provided to contractor at the jobsite, with a copy to the Project Manager, prior to bringing any material onto the project site. subcontractor shall advise contractor in writing of all flammable or toxic materials which the subcontractor plans to store or use at the jobsite and shall obtain contractor’s written approval prior to any such use or storage of material. subcontractor willfully comply with all OSHA Hazard Communication requirements including all training required of employees and subcontractors. * Subcontractor shall hold weekly safety and training meetings with employees and supply contractor with a list of employees who attended and topic(s) discussed. * All subcontractor employees will attend all contractor Safety Meetings. Subcontractor shall designate one employee as the “Safety Representative” who shall be responsible for the jobsite implementation of all subcontractor’s safety programs and requirements. * Subcontractor shall provide, erect, maintain, dismantle and remove on completion of its work all barricades, railings, covers and safety netting required to complete its Work in accordance with OSHA and all other applicable code requirements. * Subcontractor shall at no time remove, alter, or render ineffective any barricades, railings or covers on the Project without written permission of contractor. * Subcontractor shall pursue the work so as to interfere as little as possible with pedestrian and vehicular traffic, and shall provide and maintain proper warnings and detour signs at all pedestrian and vehicular closures, intersections, and along detours, directing traffic around closed portions of walkways or roadways. subcontractor at its expense shall, wherever necessary
Boiler and pressure Vessels Operating procedures
Electrical Safety Guidelines
Lock-Out/tag-Out
Guidelines on Confined Space Entry * The following steps are to be followed when preparing the confined space for entry: * If warning signs or barriers are to be used to prevent unauthorized entry or to protect entrants from external hazards, they should be placed on or around the confined space. * Place all tools, safety equipment, monitoring equipment, etc., near the confined space. * Isolate all mechanical and/or electrical hazards. * Purge or ventilate the confined space. * The entry supervisor will test the atmosphere If oxygen content is less than 19.5% or greater 21.5%, perform additional ventilation. Then, shut off ventilation equipment and re-test the oxygen content. If oxygen content is between 19.5% and 21.5%, continue entry preparation. * The entry supervisor will test for flammable gas level. If the meter reading is less than 10% of the lower explosive limit (LEL), continue entry preparations. If the meter reading is above the 10% of the LEL, continue ventilation of the confined space. Then shut-off the ventilation and continue the atmosphere re-tested.

Material Safety Data Sheets (MSDS)

1. IDENTIFICATION OF THE PRODUCT Product Name/s: | Variant/s | Manufacturer’s Product CodesFinished Goods Code: Formula Code: | Domestos | Domestos | All pack sizes | 61100013 | Domestos | Mountain Fresh | All pack sizes | 61100109 | Domestos | Citrus Fresh | All pack sizes | 61101101 |

2. FIRST AID MEASURES
General Advice: If poisoning occurs contact a doctor or Poisons Information
Centre. Phone 131126 in Australia or 0800 764 766 in New
Zealand.

Ingestion: Remove product from mouth. Drink 1 or 2 glasses of water (or milk). If large amount swallowed or symptoms develop contact a doctor or Poisons Information Centre. DO NOT induce vomiting.

Eye contact: Hold eyes open, flood with water for at least 15 minutes and obtain medical attention.

Skin contact: Remove contaminated clothing and wash the skin thoroughly with water. If symptoms occur seek medical advice.

Inhalation: Remove from source of exposure to fresh air. Obtain medical attention immediately.

Symptoms: Symptoms may vary depending on the level of exposure

Notes to physician: Symptomatic and general supportive treatment should be given.

Treatment: Treat Symptomatically

3. FIREFIGHTING MEASURES

Suitable extinguishing media: Extinguish with water, CO2, foam or dry chemical.

Specific hazards: Not flammable but may give off toxic fumes if involved in a fire.

Hazards from decomposition products:
Decomposes when heated, and under fire conditions, and at
>35°C may emit toxic Chlorine gas. Reacts with acids and may produce dangerous levels of toxic Chlorine gas.

Precautions for fire fighters and special protective equipment: Fire fighters should wear self-contained breathing apparatus for risk of exposure to decomposition products.

BUILDING AND FACILITIES SAFETY MANAGEMENT/GUIDELINES

General Permit to Work (PTW)

Mechanical Permit to Work

Electrical Permit to Work

Guidelines on Building Repairs and Maintenance Work

Buildings and facilities * Adequate working space MUST be provided. Design of building and facilities MUST permit easy and adequate cleaning, prevent the entrance and harboring of pests and prevent the entry of environmental contaminants such as smoke and dust. * General areas and social facilities (e.g. entrance lobbies, reception areas, canteens, rest rooms, changing areas) MUST not open directly onto food handling areas and MUST be kept clean. * Where natural drainage is inadequate, external drainage MUST be installed

The Manufacturing Area * Buildings and facilities should be soundly built, suitable for the intended purpose, of non-toxic materials and allow effective maintenance and housekeeping in all areas. * All opening windows MUST be screened to prevent the ingress of pests and shatter proofed to protect against breakage. * All floors and drains MUST be designed to meet the demands of the process, and withstand cleaning materials and methods. They MUST be impervious and maintained in good repair. * All floor drains MUST be adequately sloped to facilitate self draining and be easily and regularly cleaned. * Where significant amounts of water are used, or direct piping to drain is not feasible, floors MUST have falls to cope with the flow of any water or effluent towards suitable drainage.

Walls * Walls MUST be designed, constructed, finished and maintained to prevent the accumulation of dirt, minimize condensation and mould growth, and facilitate cleaning.

Ceilings / Overheads * Ceilings and overheads MUST be designed, constructed, finished and maintained to prevent the accumulation of dirt, minimize condensation and mould growth, and facilitate cleaning. * Where suspended ceilings are used, adequate access to the void MUST be provided to facilitate cleaning, maintenance of utilities and inspection for pest activity.

Layout, Product Flow and Segregation * The process flow from intake to dispatch MUST be arranged to minimize the risk of product contamination or deterioration. * Physical barriers or demonstrably effective procedures MUST be in place to minimize the risk of the * contamination of deterioration of raw materials, intermediate / semi processed products, packaging and finished products with particular consideration given to handling requirements for specific materials * If physical segregation is deemed necessary, based on HACCP/Risk assessment, this MUST take into account the flow of product, nature of materials, equipment, personnel, waste, airflow, air quality and utilities provision. * Based on HACCP/risk assessment, the cleaning of production utensils MUST be carried out in segregated areas or at specific time periods separated from the production process. * Cleaning and inspection of areas and equipment MUST be aided by the avoidance of obstructions and where appropriate the provision of adequate space. * Temporary structures constructed during building work or refurbishment etc MUST be designed and located to avoid pest harborage and potential contamination of products.

Laboratory and Control Facilities * Laboratories MUST be installed in separate rooms and MUST not open directly onto the production hall. Exception: small facilities for in-line checks of weight, sensory attributes, moisture etc * Control facilities for measurements directly at production lines MUST be set up such that controls can be performed without causing contamination to ongoing production. * Laboratories handling pathogens MUST be designed and operated to the appropriate standards to prevent infection of staff and contamination of plant or products. If this is not possible then Pathogen testing MUST be subcontracted to an external laboratory. * Where routine testing laboratories are present on a manufacturing site, they MUST be located, designed and operated to eliminate potential risks to product safety. Controls MUST be documented, implemented and MUST include consideration of the following: * Design and operation of drainage and ventilation systems * Access and security of the facility * Movement of laboratory personnel * Protective clothing arrangements * Processes for obtaining product samples * Disposal of laboratory waste * Where the company undertakes or subcontracts analyses which are critical to product safety or legality, the laboratory, or subcontractors MUST have gained recognized laboratory accreditation or operate in accordance with the requirements and principles of ISO 17025. Documented justification MUST be available where accredited methods are not undertaken. * Where the company undertakes or subcontracts analyses which are critical to product safety or legality, the laboratory, or subcontractors MUST have gained recognized laboratory accreditation or operate in accordance with the requirements and principles of ISO 17025. Documented justification MUST be available where accredited methods are not undertaken. * Procedures MUST be in place to ensure reliability of laboratory results, other than those specified in This MUST include: which: * Use of recognized test methods, including Unilever specific methods where available * documented testing procedures * Ensuring staff are suitably qualified and / or trained and competent to carry out the analysis Required * Use of a system to verify the accuracy of test results e.g. ring or proficiency test * Use of appropriately calibrated and maintained equipment

Sanitary Facilities, Changing Facilities and Toilets * Designated, adequate, suitable and conveniently located changing facilities and toilets MUST be provided for all personnel (staff, visitor or contractor). These MUST be sited to allow direct access to the production, packing or storage areas without recourse to any external area. Where this is not possible, a risk assessment MUST be carried out and procedures implemented accordingly e.g. the provision of cleaning facilities for footwear. * The facilities MUST be kept in a good and clean condition, well lit, ventilated and where appropriate heated. * Where an operation involving high risk (refer to glossary) products exists, personnel MUST enter via a specially designated changing facility, and MUST follow specified procedures for applying visually distinctive clean overalls, headwear and footwear. * Storage facilities of sufficient size to accommodate all reasonable personal items and outdoor clothing MUST be provided for all personnel who work in raw material handling, processing, preparation, packing and storage areas. * Outdoor clothing and other personal items MUST be stored separately from work wear within the changing facilities. * Suitable and sufficient hand washing facilities MUST be provided at access to, and at other appropriate points within, production areas. Such hand wash facilities MUST provide as a minimum: * Sufficient quantity of water at an appropriate temperature * Liquid soap * Single use towels or suitably designed and located air driers * Advisory signs to prompt hand washing and appropriate instructions for use (including consideration of appropriate language). * Where high risk (refer to glossary) food products are handled, the following additional requirements MUST be provided in addition to the points above: * Water taps with hand free operation * Hand disinfection.

* Toilets MUST be adequately segregated from production, packing and storage areas and MUST not open directly into production, packing or storage areas. Toilets MUST be provided with hand-washing facilities comprising: * Basins with soap and water at a suitable temperature * Single use towels or suitably designed and located air driers * Advisory signs to prompt hand washing and appropriate instructions for use (including consideration of appropriate language). * Designated controlled smoking areas MUST be isolated from production areas to an extent that ensures smoke cannot reach the product. Where smoking is allowed under national law, sufficient extraction to the exterior of the building MUST be ensured. Adequate arrangements for dealing with smokers’ waste MUST be provided at smoking facilities, both inside and at exterior locations. Facilities MUST be available, with adequate reminders, for hand washing after smoking. * All food brought into manufacturing premises by staff MUST be appropriately stored in a clean and hygienic state. No food MUST be taken into storage, processing or production areas. * Where catering facilities are provided, these MUST be suitably controlled to prevent contamination of product. * Where eating of food is allowed outside during breaks, this MUST be in suitable designated areas with appropriate control of waste. * Facilities for visitors and contractors MUST be such as to enable compliance with the company’s hygiene policy.

Work at height

Furnitures/Fixtures Repairs

Cleaning of Air Curtains and Air Shower

ENVIRONMENTAL GUIDELINES AND PROCEDURES:
Waste Water Treatment Operation

* Re-circulated water MUST have a distribution system which is separate from the potable water system and that can be easily identified.

Waste Water Sampling

Air Emission Sampling

Solid Waste Segregation and Disposal

* Our factory in Paco, Manila adheres to environmentally compliant and ISO certified processes to ensure that no harmful wastes come out of Unilever’s plants .Garbage is one of the biggest environmental issues facing Metro Manila and many other cities. In Unilever, we want make sure that our operations have minimum possible effect on the environment. Project Eliminate was created to target ZERO LANDFILL in our plant and offices. The target was reached in 2004 and the company has maintained it since then, concentrating on the following goals: * Reduce / Avoid – through Total Productive Maintenance (TPM), we improved our process and reduced waste by 80%. Furthermore, as plastic is made from oil, we developed a process to use the residual packaging waste as a co-fuel for cement manufacture. * Reuse – sort all recyclable which cannot be avoided and develop processes to treat the waste that cannot be recycled.

* Recycle – a lot of our landfill can be recycled directly. Teams were put in place toimprove sorting on the production lines. Now, we sell carton and plastic torecyclers and as a result, our garbage was reduced by 50%.

Hazardous Waste and Labeling and Disposal

* Suitable, sufficient and suitably labeled/marked refuse and waste containers MUST be provided which MUST be emptied at appropriate frequencies and maintained in an adequately clean condition. * Storage areas for waste material MUST have a hard surface, adequate drainage and provisions to keep the area clean and tidy. * Waste MUST be stored in such a way that access by pests and contamination of product, potable water, equipment, buildings or roadways on the premises is prevented. Waste containers MUST be distinctly marked and regularly cleaned. * Where agreed with the customer, suitable and sufficient containers MUST be provided for collection of substandard trademarked materials. Where agreed, such materials MUST be rendered unusable through a destructive process. All materials disposed of MUST be recorded. * If substandard trademarked materials are transferred to a third party for destruction or disposal, that third party MUST be a specialist in appropriate waste disposal and MUST provide records of material destruction. * The company MUST ensure that third party waste disposal contractors are licensed in accordance with the requirements of local law. * Systems MUST be in place to avoid the accumulation of waste in production areas, and MUST prevent the use of unfit materials. * Where appropriate, waste MUST be categorized according to legislative requirements based on the intended means of disposal, segregated and collected in appropriate designated waste containers. * Waste disposal MUST meet legislative requirements. Where licensing is in operation for disposal of categorized waste, it MUST be removed by licensed contractors and records of disposal MUST be maintained and available for audit. * External waste collection containers and rooms housing waste facilities MUST be managed to minimize risk. These MUST be: * emptied at appropriate frequencies * covered or doors kept closed as appropriate * Requests to transfer substandard material to charitable organizations MUST be approved by Unilever

Requirements For Securing Environmental Permits

Submission of Periodic Periods

Identified Aspects and Impacts

Selection of Hazardous Waste Treater and Transporter