1.0 PURPOSE
1.1 To establish a systematic plan for effective management of an accident/incident and to minimize environmental impacts and losses to people and property. This Emergency Preparedness Plan describes the emergency preparedness of the manufacturing unit and is applicable to deal with various types of emergency situations, which could occur within the factory premises. The ERP has been formulated on the basis of the requirement Clause 4.4.7 of ISO 14001-2015/ OHSAS 18001-2007.
2.0 SCOPE
2.1 This procedure covers all the activities required to prepare for and respond to any emergency situations including both accidental and deliberate on-site. It implies to all management and staff personnel as indicated in the manufacturing unit.
3.0 RESPONSIBILITY
3.1 HR Officer and above shall be responsible for the preparation & execution of this SOP.
3.2 HR & QA shall be responsible for the review of this SOP.
3.3 HR Head and QA Head shall be responsible to ensure compliance of the procedure and implementation of this SOP respectively.
4.0 DISTRIBUTION
4.1 Quality Assurance
4.2 Quality Control
4.3 Production
4.4 Warehouse
4.5 Engineering
4.6 Human Resource
4.7 Analytical Laboratory
4.8 Environment, Health, and Safety
5.0 DEFINITIONS
5.1 Definitions
5.1.1 Event or circumstance that may significantly impact operations. This includes any sudden, unexpected occurrence, natural or human-caused, which poses a significant threat to the activity going around the premises.
6.0 ABBREVIATIONS
6.1 Abbreviations
6.1.1 QA : Quality Assurance
6.1.2 HR : Human Resources
6.1.3 SOP : Standard Operating Procedure
6.1.4 ID : Identification
6.1.5 ABC : Ash Barrel Current
6.1.6 DCP : Dry Chemical Powder
6.1.7 Km. : Kilometer
6.1.8 Kva : Kilovolt Amp
6.1.9 CCTV : Closed Circuit Television
6.1.10 GMP : Good Manufacturing Practice
6.1.11 HR : Human Resource
6.1.12 Ft : feet
6.1.13 QC : Quality Control
6.1.14 No : Number
7.0 PROCEDURE
7.1 Risk assessment & evaluation:
7.1.1 The HR team/Safety team/QA team shall periodically evaluate potential risks to the unit due to emergency occurrences.
7.1.2 Risks due to emergency situations are assessed and prioritized on the basis of their probability and seriousness. The QA/QC team forwards written results and recommendations for preventive and/or contingency actions to the emergency management team for review and incorporation into the emergency response plan.
7.1.3 Identified risk may be categorized as natural or caused by human actions and the latter may be broken down into accidental and intentional. Situations that have the potential for creating an adverse impact on the company’s operations and safety may include (but are not necessarily limited to) the following:
7.1.4 Each potential risk is evaluated and contingency plans are identified as follows:
7.1.4.1 Fire: The Major Potential Hazard in the Plant is Fire and/or Explosion in Diesel, Lubricants, Fire in combustible materials in Administration Block, Small Fires in Combustible packing materials, Fire in electrical equipment, Fire in LPG Cylinders used in the canteen, Fire in D.G. Room. In case of fire breakout, ABC /DCP/ Mechanical Foam fire extinguishers are installed in areas where the fire might occur; such as outside /inside of every unit, maintenance area, and inside plant premises. Safety Officer or any authorized personnel shall take over the responsibility in case of any emergency.
7.1.4.2 Power Cut: In case of a power cut, two generators are installed. The two generators have the capacity to support power supply throughout the Plant, including all systems, chillers & ovens etc.
7.1.4.3 Gas Cylinder: To prevent incidences of gas leaks or cylinder bursts. Gas storage has been allotted outside in an open area, away from the manufacturing area & office premises.
7.1.4.4 Flood: The production premise is at least ---km away from any river bank. And it is constructed in such a way that it is at a height higher than the surrounding areas & a proper drainage system, which enables proper water flow during heavy rain.
7.1.4.5 Theft: Any type of theft inside the plant could be taken care by all means of precaution with help of security personnel who are present in the premises round the clock and CCTV is distributed all over the area of the manufacturing unit.
7.1.4.6 Earthquake: In case of tremors the personnel in charge of the sections is supposed to turn off the main switch and lead all the workers to the open area after the tremors stop.
7.1.4.7 Human Causes including labor strikes: No labor union concept is regulated in the company. To avoid all these circumstances HR holds one on one meetings with all workmen and keeps in regular contact with them while they take the rounds. A grievance register is also maintained.
7.1.4.8 Equipment failure: As soon as we get information, the main switch is shut, and then needful corrective and preventive action is taken immediately in consent with departments involved.
7.1.4.9 External Issues like raw material interruptions: To avoid interruptions we have Purchase and Procurement department who forecasts the raw material required as per demand of the market and inventory present.
7.1.4.10 Bio vigilance and Bioterrorism: Bioterrorism can be prevented by adopting a Security Plan, GMP which includes procedures like unauthorized access to the Laboratory, an inspection of incoming materials, and all sections under lock and key. The keys are under time office/security surveillance. We have deployed security round the clock so that no such incident could happen. Besides these electronic cameras have been installed in different areas of factory premises to capture any footage.
7.1.4.11 All records shall be retained by the Emergency team leader/Safety Officer/ HRD. These reports shall include the names of all persons involved in the continued planning and writing of this plan.
7.2 Emergency response planning
7.2.1 Medical Aid facilities: The Medical Clinic Room is maintained, under the charge of a qualified Doctor. An ambulance is also maintained to transport the injured persons from the affected site.
7.2.1.1 Clinic room: The following medical equipment is available in the Clinic room
Blood Pressure measuring apparatus, Stethoscope, Weighing scale, First Aid kits, Torch, Suction apparatus, bed, and nursing cabin maintained with all required medicines. One permanent in-house doctor and male nurse have been appointed to facilitate medical aid in the General shift. The manufacturing unit also has a tie-up with an outside Hospital which is located about ...Km from the plant.
The address and telephone directory of the persons in other factories under the mutual - aid scheme to be contacted during normal working hours and odd hours is given on the red page.
7.2 DETAILS OF PERSONAL PROTECTIVE EQUIPMENT AVAILABLE:
Following Personal Protective Equipment are available
7.2.2.1 Hand Gloves
7.2.2.2 Fireman Helmets
7.2.2.3 Torches
7.2.2.4 Industrial Safety Helmets
7.2.2.5 Gloves(Electrical Safety/ Leather)
7.2.2.6 Safety Goggles
7.2.2.7 Aprons
7.2.2.8 Safety Belts
7.2.3 FIRE FIGHTING ARRANGEMENTS AND FACILITIES AVAILABLE:
7.2.3.1 FIRE HYDRANT SYSTEM: Exact numbers of hydrant points should be provided to cover the complete plant. By the side of the hydrant point hose Boxes should be provided. The hydrant line is always kept pressurized through a jockey pump. Keep the electrically driven Fire Pump of sufficient capacity. Alternate power supply arrangements should be made for the fire pumps.
7.2.3.1.1 Maximum Water Capacity: The Company has a firewater reservoir capacity of ....... Liters capacity, the construction for the same is ongoing.
7.2.3.1.2 Power Supply Arrangements To Run Water Pump: The Company has D.G. sets, as an additional source of power supply.
7.2.3.2 FIRE EXTINGUISHERS: A complete network of fire fighting equipment & accessories has been installed within the factory premises. The Types & No. of equipment and their locations within the premises are shown below. Call Points are used to communicate emergencies to the employees. The Safety Officer/ Section charge/ Authorized Person present at the time of the incident will declare the emergency after carefully assessing the severity of the incident at the site. He/She shall order to communicate emergency ahead.
Sr. No. |
Point Of Installation |
Class of fire |
Type of Extinguisher |
Qty |
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7.3.1.1.1 On getting the information and after assessment of the situation with the section in-charge (Site incident controller) the security in-charge will sound the emergency siren / announce the situation.
7.3.1.1.2 Section in-charge and / or security in-charge will alert all sections in the vicinity of emergency site.
7.3.1.1.3 Site incident controller and/or security in-charge will inform the main incident controller, emergency coordinator, and essential personnel on the telephone with the help of a telephone list. The telephone list is available in the Gate / Security Office.
7.3.1.1.4 The person giving the information should have a clear idea and full details regarding the incident, and then only he shall be able to ask for proper help.
7.3.1.1.5 Incident controller will made efforts to control the emergency at plant level and make the assessment of emergency situation. In case the emergency situation is not controllable at section / plant level and evacuation / outside help is required, he will declare the situation as major emergency.
7.3.1.2 EVACUATION: On declaration of major emergency the Office staffs, workmen shall rush out through the safe passages and assemble at the assembly points after getting the information from their supervisors / In-charge. Points to be noted while evacuating the workplace.
7.3.1.2.1 Do not panic.
7.3.1.2.2 Do not waste your time in switching off computers / collecting your belongings.
7.3.1.2.3 Do not run, walk brisk.
7.3.1.2.4 Do not try to overtake / push others while Getting out.
7.3.1.2.5 Always walk on the left side of the staircase.
7.3.1.2.6 Assemble at the designated assembly points in your department queue.
7.3.1.2.7 Come out through the emergency Exit which is nearest to your work place.
Notes:
* In case of fire / smoke, crawl to escape. Use a wet handkerchief to cover your nose.
* In case of earthquake, move out of the complex, to the nearest open area.
* In case of earthquake, do not stand near glass windows and walls.
7.3.1.3 CONTROLLING THE SITUATION :
7.3.1.3.1 Main incident controller will assess the situation of emergency and direct the operations to control the situation. He will also direct both emergency and plant shutdown operations.
7.3.1.3.2 All emergency coordinators will start the emergency control operation under the guidance of the Works Main Controller in accordance with the duties and responsibilities assigned to them.
7.3.1.3.3 Fire and rescue team will start fire fighting, rescue, and fogging operations as necessary.
7.3.1.3.4 Depending upon the situation, Main Controller will decide to inform and liaise with external authorities and neighboring industries for help.
7.3.1.3.5 Attention to injured: The Plant first aiders will immediately be summoned for giving first aid to the injured and they should arrange for hospitalization of the victim on the guidance of medical coordinator.
7.3.1.3.6 Engineering team will: Ensure electrical/mechanical isolation.
7.3.1.3.7 Firefighting operation: Trained fire-fighting workers and Security staff shall start the fire-fighting Operation with the general guidance of the Safety / Security Officer.
7.3.1.3.8 Security Service will:
7.3.1.3.8.1 Stop unauthorized entry.
7.3.1.3.8.2 Allow immediately the entry of emergency vehicles like fire brigade. Ambulance etc. and directs them to proceed to the affected area.
7.3.1.3.8.3 Receive the help under mutual aid and direct the persons of mutual aid to the affected site.
7.3.1.3.8.4 The guard inside shall control internal traffic and ensure that truck cars are moved out of the gate.
7.3.1.4 ACCOUNTING FOR PERSONNEL:
7.3.1.4.1 A list of employees present on duty, contractor workers, and visitors shall be maintained on a daily basis.
7.3.1.4.2 At the emergency control center, the time office in charge / his nominee shall collate the lists of personnel arriving at the assembly points with those involved in the accident. These should then to be checked against the nominal roll of those believed to be on site, updated with known changes for that day.
7.3.1.4.3 Where it is possible that missing people might have been in the area of the emergency, the emergency controller shall be informed and arrangements shall be made to organize further search.
7.3.1.5 TERMINATION OF EMERGENCY:
7.3.1.5.1 After declaration of the termination of emergency all key personnel will assemble in control room or assembly point or as directed by the works main controller for planning for the rehabilitation.
7.3.1.5.2 All evidences of the occurrence will be maintained at site and anything will not be disturbed / displaced to help the investigation and fact-findings.
7.3.1.5.3 Main incident controller will direct rescue operation to minimize the further losses to life, property and environment.
7.3.1.6 SPOKESPERSON: Unit Head or Factory manager are authorized to release the information to outside agencies. Other employees are not supposed to release any information. Inquiry made to other employees / officials shall be directed to the above officials.
7.3.1.7 RE-ENTRY PROCEDURE:
7.3.1.7.1 After ensuring that no danger to life property and environment exists, Investigation shall be carried out to find out the root causes of occurrence and suggest remedial measures. The affected part of the plant / equipment / building will be inspected, examined and tested. Environment of the affected area will be tested for the presence of accumulation of any dangerous substances. The key persons will be allowed to enter in the affected area with adequate care and personal protective equipment. After completion of maintenance and test of plant / machine / equipment, these will be run on trial followed with normal production.
7.3.1.7.2 All activities during the emergency will be noted down for further improvement in the plan. Record of damage and repair to plant/equipment/machine will be prepared and preserved for further reference.
7.4 PREVENTIVE SUPPORT:
7.4.1 TRAINING AND AWARENESS: Regular training is given to employees for their roles and responsibilities during the emergency and they are also appraised about the various potential emergency situations. Notices and Posters are displayed for spreading awareness to the employees and workmen. The Security Gate informs visitors to the Factory on where to assemble during an emergency and their Do’s and Don’ts.
7.4.2 MOCK DRILLS: Mock drills are carried out as and when required to check the effectiveness of the emergency response as per the Emergency Preparedness Plan.
7.4.2.1 Action
7.4.2.2 Detection / Alertness of Fire Hazard
7.4.2.3 Announcement of Fire/ Hazard Alarm
7.4.2.4 Assembling at Emergency Area
7.4.2.5 Head Count
7.4.2.6 Extinguishing the Fire
7.4.2.7 Restoration of Normalcy.
7.4.3 FIRST AID: First aid boxes are available at different locations. The contents are regularly checked and replaced as necessary by HR. First Aiders are present in all the sections under Manufacturing Unit.
7.4.4 CONTINUOUS SURVEILLANCE OF OPERATIONS: All operations are continuously kept under surveillance; HR takes round in each section every hour. Do’s and Don’ts are followed for preventing any emergency. Besides, a meeting of the Management Review Committee shall be convened to analyze the actions taken and loss encountered, suggesting/incorporating any corrective and preventive mechanisms, and modifying the Emergency Response Plan. As required, further training shall also be provided to the personnel.
7.4.5 The following information is included in the emergency response plan:
7.4.5.1 Emergency services contact information.
7.4.5.2 Emergency phone numbers, report forms, and emergency instructions
7.4.5.3 Description of emergency warning devices and signals, such as sirens and alarm lights
7.4.5.4 Designation of responsibility for evacuation of employees, visitors, staff, etc.
7.4.5.5 Placements of fire extinguishers, emergency exits, gas and water valves, electrical power shut-off devices, first aid kits, and instructions for the safe and effective operation of each device.
7.4.5.6 List of critical records & data to be secured and directions for securing them.
7.4.5.7 List of personnel to be contacted and criteria for making contact with each.
7.4.5.8 Emergency procedure training records.
7.4.5.9 Emergency Preparedness Map.
7.4.5.10 Activities conducted in the course of responding to an actual emergency or testing shall be recorded in an Emergency activity log.
7.5 The QA shall maintain the records of the emergency response plan and emergency activity log, related to food safety emergency response or testing, in accordance with the food safety records.
8.0 REFERENCES
8.1 References
8.1.1 In-house
END OF THE DOCUMENT
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