Purpose. Area of application. Definitions. Responsibilities. General requirements. Contents. Documents. Flowchart. Decommissioning. Risk Assessment. Dismantling. Installation of machine. Determine project group. Set up action plan. Incorporate in project

1. PURPOSE

The purpose of this instruction is to ensure that all projects regarding used and/ or new machines shall be assessed for their potential hazards and that risks will be eliminated before final handover to the plant (end of the project). Projects involving used machines are completed in such a way that the standard of safety equipment is up to date according the ALARP principle.

2. AREA OF APPLICATION

Mondi Europe & International Converting Business Unit Operations

3. DEFINITIONS

· ALARP:As Low As Reasonably Possible.

· RA:Risk Assessment.

· CAPEX: Capital Expenditures

· OPEX: Operational Expenditures

4. RESPONSIBILITIES

Plant MD’s are responsible for the correct implementation of this instruction.

5. GENERAL REQUIREMENTS

The applicable law applies.

6. CONTENTS

See next page

Documents

Flowchart

6.1 Decommissioning

When a machine is decommissioned and the decision is made not to scrap the machine, this instruction needs to be applied.

6.2 Risk Assessment

Before a machine is dismantled in a plant, the local team (if necessary with help of BU SHE Co) needs to do a complete RA on the operational processes of the machine. If there’s already a RA available then this RA needs to be thoroughly evaluated in order to ensure it is up to date.

If the machine is mothballed the RA needs to be done in the English language and needs to be saved locally and by the BU SHE Co.

6.3. Dismantling

Dismantling of the machine incl. the existing safety equipment which needs to be stored/ shipped with the machine (for dismantling a machine the applicable Mondi procedures need to be followed).

6.4 Installation of machine

This relates to both new and used machines.

6.5 Determine project group

A project group needs to be formed with clear roles and responsibilities. Members of the project group should be at least, but are not limited to:

- Project leader (local and operations team)

- Local SHE coordinator

- Local maintenance manager

- Contractor responsible

- ...

The project group is responsible for the correct implementation of this instruction. The project group shall meet on determined intervals in order to discuss progress, initiated by the local SHE coordinator.

SHE (RA, training, guarding, procedure, CAPEX/OPEX, environmental impact, etc.) shall be a fixed agenda point during project group meetings.

6.6 Set up action plan

Before start of the project a well –founded action plan shall be developed, initiated by the local project manager. This is a written plan where all relevant info/ (possible) actions regarding SHE are listed, such as RA’s to be done, guarding already in place, additional guarding (best possible solution, ALARP,...), what training is necessary after installation, ergonomic issues, is there any potential environmental impact, etc.

6.7 Incorporate in project plan

The output of the action plan (6.6) shall be input for the overall project plan, including responsible parties, deadlines, milestones, etc.

6.8 Pre-start RA

Before the (purchase) contract is signed a RA shall be carried out on the machine and the tasks that people will perform, input shall be the RA done by the supplier of the machine. If this is a used machine from within the Mondi group than the (possible) existing RA will be input for this pre-start RA. As far as possible the typical RA topics shall be incorporated, such as (but not limited to):

- Normal operation (intended use as well as foreseeable un-intended use)

- Set up

- Maintenance

- Emergencies

- Cleaning

- Installation (f.i. segregation of pedestrian vs. FLT traffic, positioning of machine, etc.)

6.9 Operational check

Before start up (i.e. before introducing process materials/ web handling) a check shall be done to ensure that the equipment and procedures are as required by previous assessments and that the projects meets company and legislative requirements.

After installation of the machine, and all the relevant SHE equipment, an operational check shall be performed. This will actually be a (or more likely multiple) test run of the machine in order to check if all the safety devices are working, if the installation is practical, if there are no additional risks, etc.

The test runs shall be performed with the help of actual operators who will be responsible to work with this machine after commissioning. Results shall be documented and if results are within specifications then the project leader will sign off for release of the consistency check.

6.10 Consistency check

After the operational check has been performed and is signed off by the project leader the last phase of the project shall be executed, the consistency check.

The consistency check shall consist of a pre-defined number of test runs in order to determine if the machine can perform according to qualifications including all implemented SHE measures. Test runs can be actual production runs for customers!

6.11 Hand over

If all SHE measures are working according qualifications and if there are no more additional risks, the machine can be handed over to the plant. After sign off by the project leader!

· SHE.CBUM.001 – Management system

· SHE.CBUM.018 – Management of change

· Mondi Joint Methodology – Risk Assessment

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