Stay healthy and stay safe.
Safety is the most important element of any work place. It needs to be the first and last thing we think about at work or home.
RULES & PROCEDURES
To help maintenance workers survive and thrive in hazardous workplaces.
How IoT-Based Network Surveillance Makes Manufacturing Smarter and safer.
Focus on learning and education.
Supplement of
PUBLISHER
Paul Burton pburton@ annexbusinessmedia.com 416-510-6756 COO
Scott Jamieson sjamieson@ annexbusinessmedia.com
MEDIA DESIGNER
Andrea M. Smith
EDITOR
Mario Cywinski mcywinski@ annexbusinessmedia.com (226) 931-4194
ACCOUNT CO-ORDINATOR
Barb Vowles bvowles@ annexbusinessmedia.com (416) 510-5103
CIRCULATION MANAGER
Beata Olechnowicz bolechnowicz@ annexbusinessmedia.com
In Co-operation with
PRESIDENT JP Giroux • jp.giroux@emccanada.org
(519) 376-0470 (866) 323-4362
CHAIRMAN OF THE BOARD, TREASURER Al Diggings • adiggins@emccanada.org
VICE PRESIDENT, MANUFACTURING SECTOR PERFORMANCE Scott McNeil-Smith • smcneilsmith@emccanada.org
VICE PRESIDENT, COMMUNITY PARTNERSHIPS AND STAKEHOLDER RELATIONSHIPS Bren de Leeuw • bdeleeuw@emccanada.org
The need for food to continue to be processed, is running into the need for companies to keep their employees safe. While most of the time, the two needs co-exist without issue. A number of food processing plants in Canada have had outbreaks of the COVID-19 virus.
The most recent example is a Calgary poultry plant operated by Sofina Foods/Lilydale, which operates 16 Canadian plants, has seen nearly 20 employees test positive for the virus. The plant did not close, but others have done just that since the pandemic began. Another Alberta plant, in High River, operated by Cargill, closed for two weeks earlier this year as almost 1,000 of its workers tested positive. A Calgary Cargill plant also had an outbreak. While an Olymel plant in Quebec had to shut down its plant, as did Harmony Foods in Calgary, while a JBS Food Canada plant in Alberta had to go down to one shift.
For many food processing plants, following strict health and safety procedures is a given, as the safety of the food supply chain is of utmost importance. As we have seen in the past what happens when those safety procedures are not followed and outbreaks of food
bourne illness happened. However, COVID-19 is a totally different problem, and while companies are doing what they can to prevent outbreaks of the virus, as mentioned above, they are happening.
Back in May, the Canadian government announced that they would be providing food processing companies with funds that they can use to purchase personal protective equipment (PPE) for their employees, as well as other items that are needed for this ‘new normal’ of life during a pandemic. Those funds are now beginning to be distributed to various plants across Canada. Hopefully, this will help to reduce the number of COVID-19 outbreaks that are happening at Canadian food processing plants. While much attention is rightly given to front line workers, such as nurses, doctors, first responders, and so on, those in the food industry deserve credit for continuing to help to keep the Canadian food supply chain going, with the risk of COVID-19 ever present. To them, I would just like to say a big thank you.
Mario Cywinski, Editor
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Safety is the most important element of any work place. It needs to be the first and last thing we think about at work or home.
BY PETER PHILLIPS
Sometimes overlooked is the safety of contractors while at work.
I ndustries place important attention to the safety of its employees; however, just as important are people working at the facility who are contractors. They may be working on a project or supporting the maintenance department on many scheduled maintenance activities.
A number of employees (including contractors) are killed at work every year in Canada. Regulatory and company internal safety programs
provide important protection for everyone in the workplace.
Focusing on contractor safety; whether a company is private or publically owned, contractors play an important role maintaining the equipment and facility. Every company has a contractor on-site on a daily bases, and it is our duty to keep them out of harm’s way.
I n order to keep contractors’ safe, companies have implemented steps that must be followed, whether the contractor is on-site for a few hours or many weeks.
Here are some of the best practices companies are following to ensure the safety of contractors while at a facility.
Let’s start with the contactor before they even set foot on the property. Assuming the contractor has the necessary liability insurance, safety policies, and other regulatory requirements. However, when contractors are hired, how can we ensure they work safely, and are safe while at the facility.
First, safety training of the person coming onsite needs to be validated. It’s important that they have safety training and their certification is up-to-date. Software is available where the contract employee can go online and document their safety certifications, and take the necessary courses needed by the facility before they arrive to work. The software is administrated by the hosting facility and they can review the contract employee’s training and validate that they have the proper credentials before the show up for work.
C ourses including plant safety orientation and other specific company training can be taken prior to their first day of work. Doing these courses ahead of time saves valuable time. People can start work shortly after they arrive instead of spending company time going
through safety orientation and completing other necessary documents.
T he facility uses work order planning and scheduling process to assign work to the contractor and the process needs to include the following important elements:
• What site work permits does the contractor need?
• What specific safety instructions and procedures do they need?
• Who is locking out the equipment?
• Who is supervising the contractor while they are on-site?
It is extremely important that adequate supervision is given to the contract employee. When they are on-site the company is responsible for their safety and well-being. Just like permanent employees, contractors need to be supervised to ensure they are following company rules and procedures. It is also important that company employees are aware of contractors on-site, where they are working and the nature of work they are performing.
A best practice is to have a contractor work location board. This is a simple drawing of the facility with magnetic markers that show the contractor work location. Communicating with all employees and contractors is important,
sometimes work overlaps between company and contractor employees, it’s important everyone knows what’s going on.
A t the end of the job it is also imperative the job is inspected to ensure all the safeties are back in place, and equipment is commissioned and working properly before it goes back into service. Many companies use checklist that are reviewed by company officials and the contractor to make sure the work has been completed and it is safe to release the equipment into operation.
It may sound like a lot of work; however, one lost time injury or fatality can ruin reputations and finances of both the hiring company and contractor. No one wants to be included in Canada’s safety statistics.
Take the time to develop policies, procedures, and safety guidelines, and follow them every single time a contractor is at the facility no matter how big or small the job might be.
Peter Phillips is the owner of Trailwalk Holdings Ltd., a Nova Scotia-based maintenance consulting and training company. Peter has over 40 years of industrial maintenance experience. He travels throughout North America working with maintenance departments and speaking at conferences. Reach him at 902-798-3601 or peter@trailwalk.ca.
To help maintenance workers survive and thrive in hazardous workplaces.
BY KEVIN D. CLARK
Misalignment is a leading cause of why industrial machinery fails, requiring millwrights and reliability engineers to make frequent checks and corrections of critical machines in all kinds of environments. This includes machines within many industries
with hazardous work areas.
Automation has reduced the need for many manual maintenance tasks. However, analyzing excessive vibration patterns and detecting misalignment issues in rotating machines still largely involves human interaction. Data often needs to be collected near running machinery
with high temperatures and motors at 3,000 or more RPMs. Just as risky it is servicing machines in plants where electrocution is a risk for anyone using handheld tools.
Even with automation and the use of artificial intelligence, the industrial workplace continues to be a physically demanding environment.
Those demands increase every year, as maintenance teams increasingly face a lack of resources, personnel, and the right tools. To assure safety while machine failures are diagnosed and corrected, and other maintenance duties are performed, rigor and standards must be incorporated into the processes and practices of the companies. Here are industry regulations, tools, and practices, helping promote safe machinery alignment and other maintenance tasks.
Fitness-for-service (FFS) is a multi-disciplinary engineering approach to determine if equipment such as vessels, pipelines, and tanks, are fit to continue operation. An FFS assessment, often done by a third party, is a standard best practice that helps reduce leaks and explosions at plants. Similarly, fitnessfor-duty exams are required for job applicants aspiring to work in many industries. This includes not only corporate applicants, but contractors and subcontractors, including those providing alignment and other maintenance functions. Many of these physical exams are valid for two years; after that, a new exam is required.
Adequate training is a fundamental need for those working with tools and machinery, and one that not all companies get right. Apprentice, mentoring, and similar programs help younger employees learn from experienced ones on how to work around machines, and how to use tools and software safely and efficiently. Meanwhile, numerous global certification programs come into play, depending on the country and industry,
and are mandatory requirements for some roles, and highly desired for others.
These include: FMTC safety courses for working at heights and in confined spaces, and NOGEPA, OPITO, GWO, and others. The U.S. Occupational Safety and Health Administration (OSHA) offers safety training, while the International Organization for Standardization (ISO) provides the industrywide ISO 45001 training for occupational health and safety plus numerous more industry-focused coursework.
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These are products designed for use inside hazardous environments. They contain equipment and wiring incapable of releasing enough electrical or thermal energy to spark fires, explosions, or electrocutions. This is especially critical in work areas where flammable gases or liquids are being handled, allowing vapors to form. Intrinsically safe products must be tested and certified to quality for this distinction by organizations such as Canadian Standards Association, ATEX, International Electrotechnical Commission, Factory Mutual, and others.
U.S. employers must obtain these permits, required by OSHA, for any areas where hazardous materials are stored and cannot be removed, or in areas where flammable atmospheres exist. These permits come with conditions, inspections, and penalties.
This equipment: from hard hats, gloves, and eye protection, to full body suits, must be worn to minimize exposure to hazards that cause serious workplace injuries. Workers in most industrial environments wear some form of PPE; full body suits are more common in “hot work” areas with
Maintenance work is vital to keeping machines up and running. However, most agree it is not worth giving up an arm or a leg — or worse — for.
petroleum tanks and where fire-producing tools are used for welding, and soldering.
LOTO is a multi-pronged approach to make sure machines and equipment are properly deactivated, and not able to be restarted during maintenance. Workers maintaining or servicing these machines may be seriously injured or killed if hazardous energy is not controlled, if idle machines are inadvertently turned back on, if machines are not adequately deenergized, or for another occurrence.
Injuries resulting from these failures or mishaps may include electrocution, burns, crushing, amputating, or fracturing body parts. Supervisors and others must be trained in lockout/tagout procedures to ensure safe machinery maintenance.
Time spent observing and working in hazardous
environments offers lessons in avoiding accidents and injuries.
Such as:
Knowing the proper distance to maintain from an operating machine to collect vibration data;
• Understanding that LOTO must be confirmed before undertaking any alignment or other maintenance work, such as attaching sensors to machines;
• Making sure that cables used for any maintenance tools don’t get stuck in a machine shaft still running;
• Focusing strictly on the maintenance job at hand, and not trying to multi-task; and,
• Avoiding smoking anywhere near an environment containing flammable liquids or vapors.
Maintenance work is vital to keeping machines up and running. However, most agree it is not worth giving up an arm or a leg — or worse — for. Stay safe.
Kevin D. Clark, CMRP, is Vice-President of Fluke Reliability. He joined Fluke in December 2016 and has over 30 years of experience in operations leadership focusing on engineering, asset management, IT, supply, manufacturing automation, and safety systems.
Manufacturing is a complex business, with many potential security risks, and health and safety guidelines to adhere to.
BY JOE MORGAN
There are many areas of a manufacturing business where IoT-based network surveillance can play a valuable role: from the car park, to entrances and exits, office areas, delivery and dispatch, and the manufacturing and assembly areas themselves.
INTERNET OF THINGS (IOT), ARTIFICIAL INTELLIGENCE (AI) AND MACHINE LEARNING (ML) 101 IoT technology is the concept of connecting any device or object with a built-in sensor to the network for the
purpose of extracting valuable data. Sensors are connected to an IoT platform, which reads the collective data and uses analytics to determine which information is useful.
IoT-based surveillance enables you to protect
both assets and occupants well beyond what’s possible with standard analog cameras, as data can be collected anywhere that can be measured by sensors, so you can address potential issues well before they escalate, and make
smarter, evidence-based business decisions. Through analytics, AI, and ML are what make specialized security applications possible, such as facial recognition, licence plate identification, virtual fences, unauthorized person and vehicle tracking, loitering, and “object left behind” flagging.
Internet protocol (IP) cameras can monitor gates and fences along the boundary of a facility, and record license plates. Businesses often have a flow of legitimate non-employees visiting the site, which makes access control vital. Even employees need access control, as some will only be authorized to enter specific areas of a facility. Door stations with integrated video and audio can enable verification.
IP cameras can also be added to an existing analog system and provide improved image quality, remote accessibility, and advanced analytics. IoT technology allows smart cameras to analyze and react to security breaches in real time. For instance, if an intruder attempts to enter the facility, a camera can send an e-mail to security, illuminate the area with a floodlight, and activate an audio alarm or a message through a loudspeaker instructing the intruder to leave immediately.
Single cameras can cover vast areas. A pan, tilt, zoom (PTZ) camera can be useful in bays with rolling doors. Each time a door opens, the camera can automatically tilt and zoom to record. Alternatively a multi-sensor, fixed field wide angle camera, can zoom in as necessary. Facility which operate 24/7, can use HD cameras that can record colour in dark conditions.
Accidents can be particularly serious in industrial sites, manufacturing facilities, and factories, and work-related injuries and illness can be costly for businesses. Video surveillance helps reduce the cost of accidents, as video can be used in post-incident investigations, and identify responsibility. The video allows the organization to take action to ensure a re-occurance doesn’t happen. That could be by using more visible signage, protective barriers, new machinery, or use of the video for employee safety education.
It’s both the employer and employee best interest to prevent accidents and incidents happening. Therefore, cameras visible in manufacturing facilities can ensure employees adhere to all health and safety guidance. When workers know that video surveillance is watching, they are more likely to follow safe working practices.
Any manufacturing facility will want to maximize production, and prevent failure of machinery – which can have a serious impact on output, leading to dissatisfied customers and reduction in profitability. IoT-based video surveillance can monitor the overall production process, while additional technologies such as thermal imaging can highlight potential issues (such as machines overheating) so that proactive action can be taken ahead of a failure. Video analytics can also be used to study the flow of people and product throughout the manufacturing plant, highlighting areas where small changes can result in big improvements in efficiency.
According to Information Technology and Innovation Foundation (ITIF) research, monitoring machine utilization in real time through IoT applications can increase productivity up to 25 per cent. IoT is also estimated to reduce factory equipment maintenance costs by up to 40 per cent and reduce equipment downtime by up to 50 per cent. IoT can also help to better manage inventory, driving optimization measures that can save up 20 to 50 per cent in factory inventory carrying costs.
Having a “smart building” through IoT based
surveillance can help with overall energy efficiency. Up to 60 per cent of a building’s total lifetime maintenance costs is spent on heating, ventilation, and air conditioning. In a smart building, utilities are only used when they are needed, rather than all the time. Adjusting lighting and temperature in large buildings can reduce heating costs by up to 25 per cent and lighting costs up to 15 per cent.
IoT can also help with better utilization of the premises, as when Building Managers know what/when/how space is being used, and by whom, they are able to fully utilize it more effectively, and utilize assets and resources to find additional income.
When choosing a security partner, be sure to carefully examine their credentials and equipment offering, and their cybersecurity measures. There is no denying that IoT-based network surveillance will continue to play a big role in the future.
Joe Morgan is the Segment Development Manager for Critical Infrastructure at Axis Communications, Inc. In this capacity, he is responsible for developing strategies and building channel relationships to expand Axis presence in markets specific to critical infrastructure in North America.
The first thought that jumps to mind when September rounds the corner is “education.”
I‘m the first to admit being one of those people who was excited when school supplies hit store shelves, and looked forward to the learning opportunities about to unfold before me in the months to come. Later in life, as a mature student, I had a much deeper sense of respect and appreciation for what education afforded. Work experience solidified the lessons taught even more. Truly, learning never ends, it continues your entire life. The subject matter may differ; educators, mentors, and peers take different forms, and classrooms change from conventional desks and chairs, to forums and conferences, supplier and customer events, books and movies, to plant floors, internet learning and virtual networking events. Along the way, teachers, mentors, and peers can lend much to our experiences helping us to grow and develop, supporting our passions in industry and beyond.
Keeping to that spirit of learning, sharing best practices, experiences, stories of inspiration, and connecting with peers, is one of the cornerstones of Excellence in Manufacturing Consortium (EMC). Now close to 30 years as a not-for-profit association, EMC welcomes manufacturers of all sizes and sectors in all provinces of Canada to engage as members. With the head office team, field service advisors throughout Canada are ready and willing to assist companies with any needs they have. Looking at the past several months, we cannot help but appreciate what
an incredible year of learning it has been. The first case of COVID-19 in Canada occurred in January and since, our lives and work experiences have changed significantly. We focused first on how to best keep our people safe, and our plants running efficiently. We considered innovative ways to move forward. Transitioning from the first wave, for the most part we have come to accept that COVID-19 precautions will remain until a successful vaccine is produced and readily available. Business must move forward and with proper protocols in place, and an ongoing heightened safety awareness regarding our roles and interactions with others, we will continue to remain as protected as possible.
There are any number of lessons to be extrapolated from our experiences to date. The impact of COVID-19 has resulted in an unexpected and challenging journey for some companies, and for others has led to new products and significant growth. It has also provided cause to rethink strategies and review business continuity plans with a larger lens. There have been customer changes, supply chain interruptions, employment shortages, and a good deal of legislation to comply with. Survival in manufacturing today requires the ability to be flexible, adaptable and innovative, and manufacturers across Canada have put this to the test, especially this year.
With education in mind, we invite you to join us in our upcoming EMC Food, Beverage, Bio and Ag Sector webinar networking event, as we explore lessons learned, unfolding opportunities, and the future of manufacturing in our industry.
EMC and Niagara College Canada have partnered on a session and present a panel discussion on Growth, Innovation and Collaboration. Appreciating our interconnectedness from a supply chain perspective, we will examine the importance of collaborating and supporting business growth and global competition. Taking seats around our virtual table will be representatives from Sobey’s, Pilling Foods Inc., Northbridge Consultants, Niagara College Canada, and EMC. We’ll be learning about the competitiveness of the sector, what innovations are going to help meet the needs of the consumer, importance of collaboration in a changing market, leading ways on idea generation, adaptation, and innovation. Through polls and breakout rooms, we look forward to hearing from participants and providing opportunities for you to virtually connect with your peers in industry as well. October 8/2020
November 17 to 19, 2020, EMC is participating in the Strategy Institute’s Food Safety and Food Regulatory and Quality Assurance Summit. The three-day forum sees the spring and fall summits combined, presenting a n opportunity for anyone interested in participating. As always, there will be presentations by CFIA and FDA, and a line-up of manufacturers and SMEs sharing information relating to conference themes. In its’ 16th year,
this forum has brought participants together from across North America searching for the latest knowledge, gaining insight from best practice presentations and subject matter expertise.
The 2020 EMC Food & Beverage Sector will end year with an educational Best Practice Session on Environmental Monitoring hosted by 3M Canada in Milton, Ontario. 3M Canada – Food Safety, in partnership with Cornell University, recently completed an Environmental Monitoring Handbook for the food and beverage industry. At this event, we look forward to exploring the concepts of environmental monitoring, including controls, risk assessments, and recalls. We are hoping that this will remain an in-person event, but COVID-19 may require us to make it virtual. December 2/2020
Complimenting our EMC networking events and Regional Strategic Interest Group sessions across Canada, there are many programs available to enhance your skills. If you would like information regarding any of the following, please reach out to us:
• Lean management, tools and methodologies;
• Human capital programs;
• Health and safety; and,
• Sales and marketing.
Supplementing these is a Online Skills and Learning Portal, which was designed to help small and medium-sized manufacturers enhance
productivity and performance. With bilingual learning on thousands of topics, courses and programs, we have something for everyone.
The EMC-Harvard Supervisory Certificate Program is a training opportunity, and uses a blended approach of online technologies and training workshops, encouraging the development of critical thinking, leadership and management skills. This program runs twice a year with the next session beginning in September.
Manufacturing Essentials Certification (MEC) for production workers and certification for supervisors are designed to engage production workers in continuous improvement methods/projects to support increased results on productivity of their companies and better employee engagement. The MEC program for supervisors encourages the development of critical thinking, leadership and team management skills with increased results on productivity, better workplace and team functioning, and employee engagement.
From coast to coast, we have embraced the concept of learning and the opportunity that comes with those experiences, whether formally or informally. We are always eager to help where we can, providing you with assistance, and resources that will take you to the next level of your journey.
September is a time to appreciate the educational opportunities we have available to us, and also where we have been and where we have yet to go. On behalf of our hosts, our presenters and EMC, we look forward to
enhancing your opportunities to learn.
How do you get involved? If you are interested in learning more about EMC and the Food Sector Initiative, feel free to touch base with Bren de Leeuw, Vice President, Community Partnerships and Stakeholder Relations (bdeleeuw@emccanada. org) anytime.
08-Oct-20
EMC & Niagara College Canada – Food, Beverage & Bio Sector Networking WEBINAR Event Pillings Foods Inc., Sobey’s, Northbridge Consultants, Niagara College Canada & EMC Growth, Innovation and Collaboration! 17-Nov-20 to 20-Nov-20
16th Annual North American Food Safety, Food Rgulatory and Quality Assurance Summit Toronto, ON www.foodsafetycanada.com An interactive Summit hosted by the Strategy Institute that provides insight from CFIA, FDA and Industry Leaders on all matters related to Food Safety.
EMC Food, Beverage & Bio Sector Networking Event
02-Dec-20
Host: 3M Canada Company – Milton, ON Best Practices – Environmental Monitoring
