Operation Clean Sweep - Logoplaste Case Study

LOGOPLASTE UK

COLEFORD PLANT

7 STEP PROCESS STEP 1 We Committed to making zero pellet loss a priority STEP 2 Assessed our Plants situation and needs STEP 3 Conducted a site wide audit STEP 4 Determined if we had appropriate facilities and equipment.

STEP 5 Do employees have and are they following the procedures.

STEP 6 Make needed upgrades in facilities and equipment as appropriate STEP 7 Raise employee awareness and create accountability.

MATERIAL FLOW CHART :: AUDIT PROCESS ▪ Each load has 1.5 billion pellets ▪ A spillage of 0.01% = 150,000 pellet “opportunities”

Lorry arrives at unloading point

Meet driver and receive documentation

Take seal off and get sample

Unlock silo port

Connect pipe to silo port

Start unloading process

Finish tipping

Pack equipment away and leave unloading point

Where spillages could occur: Not likely Average High

MATERIAL FLOW CHART :: AUDIT PROCESS

Silo pipe work

Factory Delivery pipe work

Material Manifold

Drier delivery pipe work

Blender/Drier

Metal dectector

Injection Machine

Material converted to preforms

Where spillages could occur: Not likely Average High

IMPROVEMENTS

IMPROVEMENTS Purchased catch trays

these are placed under the sampling port on the vehicle.

They are also be used to empty pipes when silo blockages occur.

Catch tray under silo ports

This contains any pellets lost whilst hooking and unhooking vehicle pipe work.

IMPROVEMENTS In 2015 all Silo pipe work was upgraded from flexi pipe to metal solid pipework.

No leaks experienced as yet.

Deep clean the silos.

Fitted skirting underneath the silo ring to contain/control spillages.

IMPROVEMENTS Information posted in Silo area

for the team and vehicle drivers to maintain awareness.

Use of air lines to blow pellets around is not allowed.

High risk drains fitted with rubber sheeting to contain any loose pellets and prevent them from entering the drains.

Making it easier to clean up any spills.

IMPROVEMENTS Silo connection ports have been enclosed to prevent wide spread pellets loss in a connection fails under loading.

Allowing for a quicker and easier containment and clean up.

Fitted mesh screens over drains directly opposite silo loading point.

Allows water through but catches the pellets.

IMPROVEMENTS Installed a vacuum in the Silo area to allow the drivers and team member to clean up any spills quickly.

Fitted mesh screens over bunded drains by the silo loading point.

Allows water through but catches the pellets.

Fit internal catch tray in larger open drains that lead to site effluent plant.

IMPROVEMENTS Drains are deep cleaned on an annual basis.

A road sweeper is used every fortnight to sweep the silo delivery ports and surrounding areas.

The inside of the silos are inspected monthly for pipe work security to detect any potential risk before a problem occurs.

A Donaldson dust extraction system is used to remove any dust from the system allowing to be prevented from entering the atmosphere.

SUPPLIER ENGAGEMENT

SUPPLIER ENGAGEMENT Main suppliers contacted to make them aware of our commitment to Operation Clean Sweep.

Suppliers engaged with a review of driver work instructions and systems used.

Signed commitment document from them.

SUPPLIER ENGAGEMENT A competition is being held for employees to help increase knowledge of OCS and our Objectives.

All answers can be found on the Operation Clean sweep web site.

Join in the Quiz and win.

Take a form from below and Return it filled out with your Answers to Martin Lock. To be in with a chance to win an £100 Meal Voucher for the Moody Cow pub in Upton Bishop, Herefordshire!

Good Luck To All!

The winner will be announced on Friday 30 th September 2016

SUPPLIER ENGAGEMENT 18 slide presentation running on Large screen TV’s

in the

Plastic Pellets Environment ZERO PELLET LOSS

STEP 1

WE COMMITTED TO MAKING ZERO PELLET LOSS A PRIORITY

STEP 2

ASSESSED OUR PLANTS SITUATION AND NEEDS

STEP 3

CONDUCTED A SITE WIDE AUDIT

STEP 4

DETERMINED IF WE HAD APPROPRIATE FACILITIES AND EQUIPMENT.

STEP 5

DO EMPLOYEES HAVE AND ARE THEY FOLLOWING THE PROCEDURES.

STEP 6

MAKE NEEDED UPGRADES IN FACILITIES AND EQUIPMENT AS APPROPRIATE

STEP 7

RAISE EMPLOYEE AWARENESS AND CREATE ACCOUNTABILITY.

COLEFORD OPERATION CLEAN SWEEP PROJECT OVERVIEW

INCREASED SIGNAGE FOR IMPROVED AWARENESS

RUBBER COVERS TO PREVENT DRAIN INGRESS

CATCH TRAY FOR DRIVER CONNECTION POINT

The Journey from GOOD to EXCELLENCE never ends!

CHANGED FROM FLEXI TO SOLID PIPE WORK

CATCH TRAY AND CONNECTION POINTS

ENCLOSURE TO PREVENT BURST PIPE SPILLS

THANK YOU.