1

Operating Procedures and Training

Presented at:IIAR 2004 Ammonia Refrigeration Conference & Trade Show,

Kissimmee, FloridaBy:

Lawrence F. “Tex” HildebrandVern M. SandersonMichael D. Axthelm

Wagner-Meinert, Inc., Fort Wayne, IN.

2

INTRODUCTION

We will discuss Techniques which can be used to:Develop Standard Operating

Procedures (SOP’s) Increase Safety Streamline Operations Reduce costs

Develop Relevant Training for SOP’s

3

Developing SOP’s (1)

Standard Operating Procedures or SOP’s are required by Federal Law. (OSHA, EPA, etc.)

Thorough SOP’s are a necessity, not a luxury!

SOP’s need to be a living document, utilized, reviewed, and modified to meet actual operating conditions.

4

Developing SOP’s (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.

5

Developing SOP’s (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.

6

Developing SOP’s (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

7

Developing SOP’s (5)

Standard Operating Procedures

should be written to the understanding of the lowest skill level of the person you

may have using them.

8

Developing SOP’s (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.

9

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.

10

Per EPA, “Costs can be greatly reduced by doing it right the first time”

Assure that process information is correct before drafting SOP’s.

Proper selection of the development team.

Utilize a “Typical” (standard) format.

How do we control costs of SOP’s?

11

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 worker’s compensation and insurance expenses to worker’s safety (SOP’s).

12

SOP’s 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.

13

SYSTEM OWNERSHIP!

14

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.

15

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 SOP’s (use representative samples).

16

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!!!”

17

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.

18

Handling Difficult Students:

Don’t 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!

19

SOP’s and Contractors

Contractors and/or contract operators must :

Use the same SOP’s as your own operators.

Be trained at least to the same level as your own operators.

20

Pitfalls of SOP’s and Training

The three most common SOP citations are:

Lack of SOP’s

SOP’s are not task-specific

SOP’s are written but not implemented

21

Summary (1)

Thorough SOP’s are a necessity, NOT a luxury!

SOP’s need to be a living document, utilized, reviewed, and modified to meet actual operating conditions.

An offensive approach to SOP’s is one of your best lines of defense!

Thorough training is required for all operators.

22

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!

23

Questions?

Thank You!

Tex