Permit to Work & LOTOTO

on the

Ballymena Michelin site

Aim of the presentation

• Introduction to Michelin Tyres.

• Information on the Ballymena site.

• Over view of our Permit To Work system.

• Over view of our LOTOTO system.

• The application of Permit To Work and LOTOTO on the Ballymena site.

Michelin as a group

74 Manufacturing locations

Algeria

Nigeria

Brazil

Colombia

United KingdomGermanyFranceItalySpain

PolandHungaryRomania

China

Japan

Thailand

United States

Canada

Mexico

19 Different countries

Russia

Michelin Daily Production

� 36 200 products marketed with a daily output of

– 844 000 tyres

– 61 000 inner tubes

– 96 000 wheels

– More than 4 million km of steel cord

– 75 000 maps and guides

World Tyre Market

MICHELIN 20.1%

GOODYEAR 16.9%

BRIDGESTONE 18.4%

OTHER 19%

YOKOHAMA 3.2%CONTINENTAL 7%

SUMITOMO 3.6%

PIRELLI 4%

Michelin Ballymena

Michelin Ballymena

• Employs approx 1000people, fluctuates with demand.

• With 200 to 300 contractors on site

• Capacity to produce 4100 Tyres per day.

• Produces 320T daily of rubber for all the UK.

• Benchmark in the Michelin group for Safety.

What is a Tyre?

• A safety device on a vehicle

• It is the only point of contact with the road and must be able to react in multiple conditions to ensure the safety of the driver, rider and passengers.

• As a tyre is such an important safety device we also want operators to be safe when making them.

Safety at Ballymena

• A continuous journey for several years to engage our people, develop our safety culture.

Safety at Ballymena

• Safety is everyones business.

• Starts a soon as you enter onto the site.

- Faced with the number of hours since our last lost time accident.

Permit to Work

• Permit to work has been used on the Ballymena site for a number of years now.

• Permit to work is a very robust system to allow people to work on machinery safely.

• There are several stages to follow when using Permit to Work.

Permit to Work

Step 1 - Isolation request

• This is in the form of a pink book. This is a request by a person to carry out an activity on a machine.

• The request can be completed by anyone however there is a need to be as specific as possible to an area being worked on or work being carried out.

• This is passed to the engineering sector who will then carry out the necessary isolation.

Permit to Work

Step 2 - Master Permit

• This is in the form of a yellow book.

• The engineering department (Coordinator) will complete the various sections of the master permit and will then arrange for the isolation to be carried out to meet the needs of the request.

• The engineering department will then issue a Sub permit to those mentioned on the request form.

Permit to Work

Step 3 - Sub Permit

• The Sub permit is a green book which is issued to cover the person working on the machine.

• This is signed by the person prior to commencing work on the machine.

• Or displayed in LOTOTO box stating what has been isolated.

• On completion of work the sub permit is returned to the engineering department.

Permit to Work

Once the Sub permit is returned to the Engineering department the engineers can then de-isolate the machine(s) allowing them to be restarted.

LOTOTO

What is LOTOTO?

• It is a lock used in conjunction with a personal identification tag to lock out an energy control device eg an electrical isolator.

• Similar to Permit to work there are 8 steps that need to be followed

LOTOTO

1. NOTIFY affected employees that LOTOTO is being performed

2. SHUTDOWN the equipment

3. IDENTIFY all lockout points

4. SEPARATE the energy from their sources

5. APPLY locks & tags

6. RELEASE all stored energy

7. DOUBLE VERIFY as required to ensure completion

8. ATTEMPT to start the equipment, leaving controls in the

OFF position

LOTOTO

• Every machine within the workshop has a process diagram and also a matrix showing what needs isolated for different tasks. These are displayed at the LOTOTO box for the machine.

CARBON BLACK WEIGHERS LOCKOUT TAG-OUT MATRIX

ENERGY SOURCE:

EQUIPMENT NAME: BN11, BN12 PLC 2 LOCATION: Group 1

Location

ELECTRICAL

24QS10 - Main Supply Isolator

Group 1 control room, Mixer Floor

106QS9 - Decoupage 1 Isolator

206QS9 - Decoupage 2 Isolator

306QS9 - Decoupage 3 Isolator

E BN 101 - LEV IsolatorIn centre of Hoist platform, front of orange LEV cabinet

labelled 1.1

PNEUMATIC

P BN 101 - CP11 Air Supply Isolator

Hand Valves on side of cabinets marked 2/CP11 &

2/CP12, located on Lower level, below Hoppers &

Feeders

P BN 102 - CP12 Air Supply Isolator

P BN 103 - LEV Air Supply IsolatorHand Valve on pipework, situated on platform above

LEV control cabinet

WATER N/A N/A

HYDRAULICS N/A N/A

VACUUM N/A N/A

THERMAL N/A N/A

GRAVITYN/A N/A

CHEMICAL N/A N/A

STEAM N/A N/A

RED TAGS

• These are used as a simple reminder aid when carrying out any isolation and are attached to the LOTOTO box or isolation point by the person who carried out the isolation. Others working on the machine sign the reverse side of the tag if in agreement and are happy to proceed with their work.

• These are then recorded by the engineering sector and checked by the engineering manager and EP at a set frequency.

Personal Padlocks

• These are issued to employees onsite with each engineering sector holding spare locks on a recordable board for contractors etc.

How does this all work together?

• All 3 systems are used together on the Ballymena plant.

• A example is illustrated on the next slide

• An isolation request is sent to the engineering team.• Engineering team creates the master permit.• Engineering team carries out the isolation as per the

LOTOTO matrices.• Engineering team issues a Sub permit.

(Sub permit is locked in LOTOTO box or given to a person)

• Engineering team locks the keys from isolation in the LOTOTO box and applies the red tag.

• People working on the machine read and sign off the red tag applying their personal lock.

• On completion the process is reversed – Locks removed, isolations lifted and sub permit returned to sector to complete the traceability of the isolation.

• Machine is able to be restarted.

Isolations

• Isolations can only be carried out by Michelin trained engineers.

Safe Access

• Some departments operate with Safe Access key exchange system - Again when entering under these conditions you must either have a key in your possession or a key must be locked in a LOTOTO box with personal padlocks applied.

Training

• In order to maintain this process we need to continually carry out checks and also train our people.

• All production people go through an annual LOTOTO validation

• All engineers go through a validation every 3 years.

Checks

• Within each department members of the management team observe each post 1 per month to discuss post safety. (OPS).

• Continual reminder about safety at work.

• These checks are also carried out on the maintenance team during different activities.

Sustainment

• In order to sustain our application of LOTOTO we meet quarterly to review and resolve any issues.

• All accidents within the Michelin group are shared between plants and reviewed to ensure a similar occurrence is prevented.

Sustainment

• Daily engineering and production teams meet to discuss results – Safety is again No1 priority at this meeting encouraging employees to raise any safety concerns they have or have seen.

Safety

is

everyones

responsibility

Thank you for your attention