• Safety

      • Safety Checks

        • Make sure to always wear the safety goggles in the Zone

        • Watch your ergonomic posture while placing carton in the Tray packer

        • Make sure to always wear the PBM earplugs in the Zone

        • Make sure to always wear the safety shoes in the Zone

        • Make sure to always wear the safety cape when you enter a machine

        • Make sure to always wear safety clothing

        • Watch out if you have to work at a certain height

        • Make sure the emergency button of the pallet is always aimed at yourself

        • Watch out for danger of burning when opening the glue supply of the OCME Traypacker

        • Always be careful if you have to work with several chemicals

        • Always be careful with danger of heat

        • Make sure you always detach the key from the switch of the roller

        • Make sure you do not cross the red line to avoid accidents

        • Watch out for turning parts of the machine (OCME) while attaching a new foil

      • Lock out - Tag out

        • Tell everyone that the area needs to be shut off

        • Identify the places that need to be blocked off and marked with a tag

        • Grab the necessary tools:

          • 2 yellow locks
          • 1 tag

        • Rotate the switch to the right to shut down the machine.

        • Attach a green lock

        • Make sure the lock is securely fastened.

        • Check if you can turn off the valve

        • Switch off the valve by turning the handle to the right 

        • Attach tag

        • Attach a green lock

        • Lock it

    • Maintenance

      • Performing a Leak detection

        • Bring the leak detector spray & the Racoord key to the working station

        • Take the leak detector & spray all joints of the aeration system

        • Wait 1 minute for the spray to have an effect

          Check visually if bubbles appear on the joints indicating a leak

        • Take the water hose & hold it in one hand towards the floor

        • Turn the handle half way down to turn the cold water on

        • Clean foam off the system & floors

        • Turn the handle upwards to turn the cold water off & wait 1 minute for the water to go down the drain

        • Put the water hose back

      • Replacing the air filter

        • Bring all the necessary tools to the working station:

          • alcohol
          • the Bunsen burner 
          • a new filter for the air supply
          • a bag for the old filter 
        • Close the air supply valve by turning the handle downwards 

        • Localise the air filter

          Filter can be found on the wort aeration (second floor of brewhouse) 

        • Open the filter cap clamp by turning it to the left

        • Take the clamp off the filter

        • Put the clamp aside

        • Take off the filter cap & put aside

        • Turn & pull filter up to take it off

        • Put filter in a bag & put it aside

        • Spray some alcohol on the sterile filter holder

        • Take the burner & slide up the safety lock to unlock it

        • Push the orange button on the burner (1 sec) to turn it on

        • Flame for a few seconds the inside and bottom of the filter holder with the burner until flames appear on the surface

        • Slide down the safety lock to turn the burner off & lock it, then put it aside

        • Take new filter that is stored in the controlling room of the brewhouse

        • Take the new filter half out of the bag

        • Place the new filter into the filter holder

        • Push filter until it can’t move any further

        • Spray a few shots of alcohol in the filter cap

        • Burn the inside of the filter cap using the Bunsen burner

           

          Wait until the flame has extinguished

        • Place the filter cap back on the new filter

        • Put the clamp back on the filter holder and close it by turning the lock

        • Flame carefully the whole aeration tube to sterilize it, exept from the flow transmitter!

        • Open the air supply valve by turning the handle to the right

        • Take used filter to the lab

      • Checking the valve

        • Check if the seal is in the right condition or if it has any damages

        • Check each part to see if they are in the right condition or if they present damage

          - springle 

          -gasket

          -quill

          -perforated ring

        • Check the inside of the non-return valve is free from blockages like:

          -Parts of gaskets

          -Wort residues

    • Operations

      • Prepare divider

        • Attach the lock for lock-out-take-out (LOTO)

        • Press on the screen of the machine on the parts that you will be working with

        • Press on the screen of the machine on the button 'loosen brake-lock'

        • Prepare your tools for use

        • Turn the fingers in the machine upwards by placing the unlocker and turning it to the left

        • Make sure the hollow side of the fingers is in line with the bulging of the can

        • Use the equipment to tighten the fingers

        • Check the correct settings for the fingers of the machine

        • Unlock setting point 1

        • Attach the turning wheel on the setting point and set it up properly

        • Place the center blocks, foil rods, spreading-conductors and tools in front of the machine

        • Loosen the screws on the center blocks and remove the center blocks from the machine

        • Unscrew the spreading-conductors and remove them from the machine

        • Unscrew the foil rod on one side

          Make sure to do this on the front side.

        • Slide the foil rods from the screws at the back of the machine

        • Adjust the foil rods to the correct position

        • Screw the foil rod tight

        • Place the correct spreading-conductors and screw these tight

        • Place the correct center blocks and screw these tight

      • Prepare the machine

        • Check the machine to see which recipe you need

        • Turn the lock to the left to loosen the spacers.

        • Take the car to your workspace and take out the spacers you need

        • Take the current spacers out the machine.

        • Take the conductors out of the machine

        • Place the right conductors after taking these of the car

        • Place the prepared spacers with the help of a second operator.

        • Make sure the coloured text is placed on the side of the lock

        • Turn the locks to the right to tighten the spacers

        • Get the fire extinguisher

      • Running the machine

        • Find the panel

        • Set up program A on the main panel by pressing the white button

        • Check the screen to see if the program has started

      • Monitor the fermentation process

        • Take self analysis recipient to the analysis desk & put funnel into the sample analysis pot 

        • Put paper filter in the funnel

        • Take one spoon of kieselguhr & put it in the paper filter

        • Take sample & poor it into the recipient until it is full

        • Move sample in the carousel recipient

        • Place recipient on the carousel 

        • Press the first button on the side to start the self analysis

        • Wait 3 minutes

        • Open & take results paper

        • Put results in the excel file on the desktop

    • 5s Standards

      • Cleaning the workplace

        • Clean the floor using a mop until it is free from product residue

        • Clean the machine parts using alcohol and a dry cloth

        • Take the current spacers out the machine.

        • Remove the boxes from the working space

        • Organize the center blocks, foil rods & tools on the table

        • Organize spacers on the table in the required order

        • Make sure the coloured text is placed on the side of the lock

      • Remove all unnecessary items from the workplace

        • Take the current spacers out the machine.

        • Remove the boxes from the working space

      • Set in order all items in the required location

        • Organize the center blocks, foil rods & tools on the table

        • Organize spacers on the table in the required order

        • Make sure the coloured text is placed on the side of the lock

      • Check the cleaning standards (hourly)

        • The conductors should be in place

        • The floor should be free from product residue

        • The center blocks, foil rods & tools should be clean & in place

    • Changeover

      • Dismantling the non-return valve

        • Bring the tools to the work station:

          1. Racoord key 
          2. screwdriver 
        • Turn the handle downwards to close the air supply valve

        • Unscrew the first nut of the non-return valve using the Racoord key

        • Unscrew the second nut of the non-return valve using the Racoord key

        • Unscrew the first nut of the non-return valve with your hand

        • Unscrew the second nut of the non-return valve with your hand

        • Pull the non-return valve to the right to detach it from between the pipes

        • Take the seal out of the valve with the screwdriver

        • Take out all the parts of the non-return valve one by one (4)

      • Re-assembling the non-return valve

        • Put all parts back one by one

        • Attach the non-return valve back by pushing it to the left between the pipes

        • Screw back with your hand the first nut of the non-return valve

        • Screw back with your hand the second nut of the non-return valve

        • Screw the first nut of the non-return valve using the Racoord key

        • Screw the second nut of the non-return valve using the Racoord key

        • Open back the air supply by turning the handle to the right

    • CILTs

      • Preparing for cleaning

        • Bring all tools from the fourth floor to the working station

          - container

          - pump

          - Racoord key

          - casings (2 long & 1 short)

        • Localize valve 1E

        • Unscrew the valve 1E

        • Place one of the longer casings over the valve 1E mouth and screw it once using your hand  

        • Take the Racoord key & finish screwing the casing until it can't move any further

        • Place the other side of the casing over the container mouth A & screw it once using your hand

        • Take the Racoord key & finish screwing the casing until it can't move any further 

        • Take the other casing & place it on the container mouth B & screw it once using your hand

        • Take the Racoord key & finish screwing the casing until it can't move any further 

        • Place the other side of the casing on the pump C mouth & screw it once using your hand

        • Finish screwing the casing with the Racoord Key until it can't move any further 

        • Place the casing over the pump D mouth & screw it once using your hand

        • Finish screwing the casing with the Racoord Key until it can't move any further

        • Unscrew the cooler water outlet

        • Place the casing on the cooler mouth & screw it once using your hand

        • Finish screwing the casing with the Racoord Key until it can't move any further

        • Close Valve A by turning it upwards

        • Open valve 1E by turning the handle downwards

        • Open valve B by turning the handle downwards

        • Open valve A by turning the handle downwards

      • Start-up the automatic cleaning

        • Plug the pump (blue) into the electrical socket (red)

        • Fill half of the container with cold water

        • Poor 2 cans of acid into the container & close it

        • Press the button on the right to turn on the pump

        • Wait for circulation 1 hour

      • Shut-down the automatic cleaning

        • Press the left button to turn off the pump

        • Unscrew valve B

        • Leave casing on the floor to drain it

        • Pick up the casing when empty & connect it to the water supply

        • Turn the handle half way down to turn the cold water on

        • Close valve A by turning the handle upwards & unscrew the casing

        • Leave casing on the floor to drain the water cooler

        • Press the button on the right to turn on the pump 

        • Take the ph paper & place it every 10 minutes in the water coming out of the water cooler to check the ph until the result is 7

        • Turn the handle half way upwards to turn the cold water off

        • Press the button on the left to turn off the pump

        • Disconnect water supply

        • Unscrew all casining from the system (valve 1 E, valve C, valve D and cooler mouth)

        • Open all valves on the cooler

        • Take all tools upstairs and place them on the foreseen holders

    • Quality

      • Taking Micro sample (SOP)

        • Check when the brewing process is half way done & bring all necessary tools to the workstation

          • own sample recipient
          • alcohol
          • Bunsen burner
        • Localize the non-sterile sample bottles to take the micro sample for lab analysis. Bottles can be found behind the door on the second floor.

        • Take a non-sterile sample bottle & hold it from underneath

        • Go to the the non-sterile sampling point to take a micro sample

        • Take cap off the lower part of the tap

        • Put bottle under the tap

        • Turn on the tap and wait until the bottle is fully filled

          Then turn the tap back off

        • Put bottle cap on and close it

        • Take micro sample to the sample platform

        • Take another non-sterile micro sample for own analysis

        • Take own sample to the sample platform

        • Take cap off the upper part of the tap 

        • Spray alcohol in the upper part of the tap & put cap on the lower part of the tap

        • Spray alcohol again in the upper part of the tap & put cap on the upper part of the tap

      • Taking QC sample (SOP)

        • Localize the sterile bottles to take a Qs sample for lab analysis. Bottles can be found behind the door on the second floor.

        • Take one of the sterile bottles and go to the sterile sampling point located behind the wort aeration

        • Spray alcohol on the bottle neck and cap & flame them using the Bunsen Burner to sterilize the bottle

        • Take cap off the lower part of the tap

        • Open bottle & put it under the tap

        • Turn on the tap and wait until the bottle is fully filled

          Then turn the tap back off

        • Flame bottleneck again to sterilize it

        • Close back the bottle without touching the rubber

          Then put bottle on the sampling table

        • Take Qc sample bottle to the sample platform

        • Take cap off the upper part of the tap & spray alcohol inside  

          Then put cap back on the lower part of the tap

        • Spray alcohol again in the upper part of the tap & put cap back on the upper part of the tap

        • Take all samples to the control room

      • Execute own sample examination

        • Take self analysis recipient to the analysis desk & put funnel into the sample analysis pot 

        • Put paper filter in the funnel

        • Take one spoon of kieselguhr & put it in the paper filter

        • Take sample & poor it into the recipient until it is full

        • Move sample in the carousel recipient

        • Place recipient on the carousel 

        • Press the first button on the side to start the self analysis

        • Wait 3 minutes

        • Open & take results paper

        • Put results in the excel file on the desktop

      • Prepare samples for the Lab

        • Write the details on the labels

        • Put labels on the bottles

        • Put bottles for the lab analysis in the refrigerator from the control room

    • Troubleshooting

      • Resuming operations after an emergency stop

        • Go to the main panel

        • Select the program you want to run

        • Press the white button to start

    • Supervisors checks

      • Check the performance

        • Is the arrow pointing to the left?

        • Is the machine running?

        • Is the seal without damages?

        • Is the inside of the non-return valve is free from blockages like:

          -Parts of gaskets

          -Wort residues