Operating Procedures and Training

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Operating Procedures and Training

• Presented at
• IIAR 2004 Ammonia Refrigeration Conference
  Trade Show,
• Kissimmee, Florida
• By
• Lawrence F. Tex Hildebrand
• Vern M. Sanderson
• Michael D. Axthelm
• Wagner-Meinert, Inc., Fort Wayne, IN.

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INTRODUCTION

• We will discuss Techniques which can be used to
• Develop Standard Operating Procedures (SOPs)
• Increase Safety
• Streamline Operations
• Reduce costs
• Develop Relevant Training for SOPs

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Developing SOPs (1)

• Standard Operating Procedures or SOPs are
  required by Federal Law. (OSHA, EPA, etc.)
• Thorough SOPs are a necessity, not a luxury!
• SOPs need to be a living document, utilized,
  reviewed, and modified to meet actual operating
  conditions.

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Developing SOPs (2)

• Standard Operating Procedures must
• Include all elements required by Federal
  Regulations as well as industry standards and
  guidelines.
• Be task specific for our industry.
• Operating Limits
• Deviations and consequences to operating limits,
  and steps to take to avoid or recover from those
  consequences.

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Developing SOPs (3)

• Standard Operating Procedures must
• Be easily understood by the operators required to
  use them.
• Be reviewed by management and operators, as often
  as necessary, to assure that they reflect actual
  operating practices and current company
  policies.
• Be certified, in writing, annually.

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Developing SOPs (4)

• Standard Operating Procedures should include
• Technical operating specifications on the
  equipment covered therein.
• Valve numbers, descriptions, functions, position
  set points
• Functional labels for all items of equipment

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Developing SOPs (5)

• Standard Operating Procedures
• should be written to the understanding of the
  lowest skill level of the person you may have
  using them.

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Developing SOPs (6)

• Standard Operating Procedures should not
  include
• Cumbersome and unnecessary details and
  information.
• Impossible to accomplish tasks.
• Confusing or easily misunderstood language.
• Instructions which are in violation of other
  company policies.

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Increase Safety

• Safety is the most important aspect of an SOP.
• Safety may be the most overlooked area of SOP
  development.
• Operators need to understand the consequences of
  circumventing safety systems.

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How do we control costs of SOPs?

• Per EPA, Costs can be greatly reduced by doing
  it right the first time
• Assure that process information is correct before
  drafting SOPs.
• Proper selection of the development team.
• Utilize a Typical (standard) format.

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Look for Cash Elsewhere

• Consult your insurance company.
• Move money from other areas of your budget (shift
  budget dollars from penalties and legal fees to
  SOP development).
• Move workers compensation and insurance expenses
  to workers safety (SOPs).

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SOPs Streamline Operations

• Allow more diversity in work assignments.
• Greater operator efficiency. (Less mistakes)
• Less key operator dependence.
• More productive use of scheduled downtime.
• Improves Operator Retention.

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• SYSTEM OWNERSHIP!

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Operator Training

• Training is required by law.
• Employee must undergo Initial training before
  being assigned to a process.
• Refresher training is required at least every
  three years, or sooner.
• Training associated with changes.

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Operators should be trained at least on the
following topics

• Awareness of hazards associated with the process.
• Overview of the process.
• Good manufacturing and safe work practices.
• Basic refrigeration principles.
• Organization, purpose, use, and limitations of
  SOPs (use representative samples).

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Methods to use for Operator Training

• Classroom training.
• Hands on training.
• Apprentice understudy to an experienced
  operator.
• Address as many senses as possible.
• I tell you and you forget!
• I show you and you remember!
• I involve you and you understand!!!

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Training Documentation

• A vital part of compliance is the documentation
  of training. This can be accomplished by
• Written exams.
• Oral exams and observation of performance by
  supervisor.
• Document the training method and results.

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Handling Difficult Students

• Dont assume a student is difficult because of
  their apparent poor attitude.
• Find their preferred mode of learning.
• Adapt training methods to motivate all students.
• Capitalize on their motivations!

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SOPs and Contractors

• Contractors and/or contract operators must
• Use the same SOPs as your own operators.
• Be trained at least to the same level as your own
  operators.

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Pitfalls of SOPs and Training

• The three most common SOP citations are
• Lack of SOPs
• SOPs are not task-specific
• SOPs are written but not implemented

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Summary (1)

• Thorough SOPs are a necessity, NOT a luxury!
• SOPs need to be a living document, utilized,
  reviewed, and modified to meet actual operating
  conditions.
• An offensive approach to SOPs is one of your
  best lines of defense!
• Thorough training is required for all operators.

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Summary (2)

• Remember that the road to safety is a continuing
  journey, not a single step a recipe that
  incorporates a great deal of common sense, mixed
  with some respect for ammonia, tossed with
  healthy portions of information, documentation
  and training!

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Questions?
Thank You! Tex
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Questions?
Thank You! VERN