Implementing "under 3 S" (Sort, Set in Order, Shine) housekeeping in a plant's specialized rooms reveals common findings and key areas for improvement that boost safety and efficiency.

 As per GM Shri Simhachalam Sir instructed to plot incharges & DGM sir enforced must to follow.

Implementing "under 3 S" (Sort, Set in Order, Shine) housekeeping in a plant's specialized rooms reveals common findings and key areas for improvement that boost safety and efficiency. 

Main Control Room

Findings:

Visual clutter on consoles: Unorganized papers, manuals, and personal items clutter the control panels, obscuring critical displays and controls.

Unlabeled cables and equipment: Unidentified and tangled cables beneath consoles make troubleshooting difficult and create tripping hazards.

Poorly marked storage for tools and manuals: Necessary tools or reference documents are stored haphazardly, causing delays when needed during an incident.

Inactive equipment: Outdated or broken equipment occupies valuable workspace. 

Improvements:

Adopt visual management: Use visual cues like color-coding and labels on panels, equipment, and cables to quickly identify functions and connections.

Implement "red tagging": Use a red-tagging system to identify and remove unnecessary items. For items of uncertain necessity, red-tag them and place them in a temporary holding area for review.

Establish designated areas: Create clearly labeled and accessible spots for operator logs, procedures, manuals, and frequently used tools.

Clear cable pathways: Use cable ties and trays to organize and route cables, eliminating potential trip hazards and creating a cleaner workspace. 

Store Room

Findings:

Overstocking and outdated inventory: Excess items tie up capital and valuable storage space. Expired or obsolete parts create confusion.

Inaccessible items: Poorly arranged and stacked materials make it difficult to retrieve items safely and efficiently.

Lack of clear labeling: Parts are not properly labeled, leading to misidentification, incorrect usage, and delayed retrieval times.

Floor clutter: Obstacles and spills on the floor create a risk of slips and falls. 

Improvements:

Perform regular stock checks: Categorize and review all stored items. Discard obsolete stock and move less-used items to designated, less-accessible areas.

Organize for accessibility: Use shelving, racks, and designated floor markings to ensure all items have a clear, labeled home. Store frequently accessed items in the most convenient locations.

Use visual controls: Implement clear, large labels on shelves and bins. Use color-coding for different types of materials, and install visual cues for stock replenishment. 

Battery Room

Findings:

Acid or residue buildup: Spills or leakage from batteries are not cleaned promptly, leading to corrosion and hazardous conditions.

Blocked ventilation paths: Obstructions hinder proper ventilation, allowing potentially explosive hydrogen gas to accumulate.

Cable clutter: Unorganized cables and charging wires pose tripping and electrical hazards.

Missing or damaged safety equipment: The eyewash station or other personal protective equipment (PPE) may be obstructed, non-functional, or missing entirely. 

Improvements:

Regular cleaning and inspection: Shine equipment and floors regularly to identify and clean up leaks immediately. Include battery terminal and connection inspections in this routine.

Ensure clear airflow: Maintain clear, unobstructed pathways for ventilation systems to operate effectively.

Secure cables: Use insulated cable management systems to organize and protect power cables, keeping floors clear.

Visible safety stations: Keep all emergency and safety equipment, such as eyewash stations and spill kits, easily visible and accessible. 

SCADA Room and ACDB/HT Panel Rooms

Findings:

Dust and dirt buildup: Dust accumulation in panel rooms can lead to overheating and potential fire hazards.

Misplaced tools and equipment: Tools left inside or on top of panels risk causing short circuits or damage during operation.

Obscured labels and diagrams: Faded or missing labels on panels and wiring diagrams make maintenance and emergency response difficult.

Storage in front of panels: Unrelated items stored in front of electrical panels obstruct access for maintenance or in an emergency. 

Improvements:

Implement "clean and inspect" routines: The "Shine" step should include regular cleaning of panels and equipment interiors with appropriate, non-conductive tools. This helps spot issues like loose connections or corrosion early.

Dedicated tool storage: Provide specific, shadowed tool boards for technicians working in these areas. Tools must be returned immediately after use.

Maintain clear visual aids: Regularly inspect and replace labels, signage, and schematic diagrams to ensure they are current, visible, and legible.

Enforce panel access policies: Use visual floor markings and signage to clearly define and protect the clear access area required in front of all panels.