Training programe

Purpose
To define the methods, frequency and the intensity of Factory Cleaning.
The PURPOSE of cleaning is to remove debris from within the plant in a sanitary and effective manner and avoid contamination from dust or foreign materials. Correct equipment and correct cleaning practice are two critical factors in the successful operation of Cleanroom management. If these two factors are closely adhered to, the Cleanroom can be maintained within acceptable limits.

Scope
1. The cleanliness of Production equipment is the responsibility of the Production staff
2. The floors, walls, sinks and windows in the Production areas, Office areas, Change rooms,
Workshops, Laboratories, Stores, Canteens, plus the toilet facilities and the Cleaner’s Store are to be cleaned on a regular basis by a team of Cleaners. Additional areas requiring cleaning, such as return air grilles, ceilings and ductwork are also the responsibility of the Cleaners on liaison with the Cleaning Coordinator.
3. Certain area of rubbish removal is the responsibility of the Cleaners. These are specified in Section 7.
4. This procedure does not provide external window cleaning and treatment of ants and spiders.

EHS Statement
When mopping, avoid creating large, wet, slippery areas.
Protective eye wear/safety glasses are to be used when: Handling chemicals, i.e. Formaldehyde

Set up limited access areas:
RED areas - Environmental Grade B
The next most stringent requirements apply in ENVIRONMENTAL GRADE B areas - Sterile Manufacture.
These rooms must be wet mopped and not polished, avoiding aeration of dust/particles, etc.
This work should preferably be carried out after production has stopped, but should production be in progress, approval MUST be obtained before commencing.
Cleaners must 'scrub-up' and dress in Sterile uniforms. Only adequately trained Cleaners are to enter ENVIRONMENTAL GRADE B areas, i.e. successful completion of sterile training

YELLOW areas - Environmental Grade C

Areas of product manufacture and or component preparation.
Liquid manufacture and Equipment preparation.
Component and Equipment Preparation room.
NOTE:
Limited access to correctly dressed staff for these areas. Cleaning
equipment is dedicated to these areas. Only adequately trained cleaners are to enter environmental Grade C areas.

BLUE areas - Environmental Grade D
Areas in which sealed product is handled. Uniforms and hats are to be worn at all times for these areas.

GREEN areas - ENVIRONMENTAL GRADE E
There are many other areas not included in the Production Environmental Grades, which must be kept clean for sanitation and staff comfort. Uniforms are not essential in these areas:
* Warehouse/Stores )
* Plant Service areas ) Environmental Grades E
* Laboratories )
* Change rooms and toilets
* Canteen
* Offices
* Corridors

To be continued...

1. Brush, vacuum, and clean the interior. Either prior to, after, or on the same day.
2. Clean wheels and tires. To avoid splash back from the wheels. Also, use tire brushes and never use them for the body of the car!
3. Wash exterior
4. Apply tire dressing
5. Polish wheels
6. Clean & Treat exterior trim
7. Polish and then wax exterior paints

Washing the Paintwork

In order to avoid deep scratches, the vehicle must be rinsed thoroughly before a sponge is applied. To do this, always begin at the top of the vehicle and rinse down. If the weather is particularly hot that day, the process will most likely require repeating, even after just a few minutes. Always make sure that the section of the vehicle that is being washed is wet. If possible park the car in a shady area. Also, morning or afternoon are preferable times.

Pour a liberal amount of soap into the bucket (making sure it is free of debris first) and then fill it up with water. Follow the manufacturers recommended instructions for which quantities of soap and water to use. Dip the sponge into the water and wait for it to absorb as much soapy water as it can. Squeeze the sponge repeatedly while swirling it around in the water. Squeeze excess water out of the sponge and then apply it to the roof of the vehicle. Always wipe the vehicle's surface in straight motions (to avoid making fine swirl marks), remember to begin with the roof and work down the sides to the bottom of the vehicle. If the weather is hot, then soap the vehicle in small sections (I.E. a panel at a time), and then rinse immediately. If not, the heat can dry the soap onto the vehicle's paint.

Washing the Wheels

It is highly recommended to use a different set of equipment (sponge, bucket etc.) for the wheels. This will reduce the risk of scratching other parts of the paint work, as the wheels are usually the dirtiest part of a vehicle.

There are two common ways to clean the wheels of a vehicle.

The first way is to clean them with soap and a wheel brush. The choice of brush rests largely on the design of the hubcaps or wheels.

First, ensure that the wheels have been rinsed with water. Next, scrub them with the wheel brush being careful not scratch the hubcaps' paint. Note: hubcaps with grooves in them can contain a lot of brake dust, as can alloy wheels. These problem areas can require extra time and scrubbing.

The second method is to use spray on, rinse off chemicals. Directions for these should be found on the bottle.

Rinsing and drying the vehicle

An important step is rinsing all of the soap off of the vehicle. Begin at the top and spray downward to avoid splashing soap back up to the top of the vehicle. If your finish has a good coat of wax , make your final rinse with water of a moderate volume and low pressure about an inch above the surface rather than a high pressure spray. This will create a sheet of water producing fewer small water beads and will improve your drying results.

Afterward, dry the vehicle with the a clean, plush microfiber towel. Microfiber towels are superior to chamois or terry towels and will prevent new scratches from appearing in the paint. As much as possible, dry the vehicle thoroughly including the nooks and crannies (door jambs, under the hood, trunk lid, etc) to prevent water spots and premature corrosion. It is not recommended to allow the vehicle to dry naturally as minerals in the water will be left behind as the water itself evaporates.

Polishing

Many products are available on the market which claim to polish paint to restore luster. Some are more effective than others, consult your owners manual or vehicle manufacturer for a recommendation for your particular car. A popular polishing tool with many enthusiasts is the clay bar. Most polishes should be applied sparingly, usually no more than once or twice per year. Never use a polishing compound on a car with a clear coat. These compounds are far too abrasive and will remove the clear coat.

To use a clay bar, the surface of the vehicle must always be lubricated. Never rub the bar on dry paint, it will scratch. Additionally, if the clay bar is dropped on the ground, it must be discarded. The contamination it picks up would subsequently be ground into the paint if it continues to be used.

Waxing

Most car wash solutions claim to have wax in them, however the amount they contain is usually not enough to offer significant protection to your vehicle. It is therefore recommended that a "hard" wax be used. These can come in a variety of forms, including pastes, liquids, and sprays. If water applied to your paint forms very large droplets or does not bead at all, it should be waxed. A general rule of thumb is to apply wax when the beads become larger than 2.5 centimeters (1 in).

Since there are a wide variety of products, follow the instructions for application on your particular product. Apply wax to one section of the car at a time, and let haze. Once this occurs, remove the wax by buffing with a folded microfiber towel. Changing to different folds often will make removal of the excess wax easier. After removal, it may be necessary to open the doors to remove wax residue at the edges of the panels.

* First remove everything. Then vacuum or dust off all crumbs. Then wet a white nylon backed sponge with cleaning solution and use the sponge side to go over the counter, including the backsplash. Let the solution set on the surface for a few minutes to soften hard droplets. Then, use the nylon side of the sponge as necessary to remove any stubborn stuff. Buff dry with a clean, lint free towel. If your countertops have lost their luster, try furniture polish or club soda to give a temporary shine to your kitchen.
* Use a mild dishwashing liquid for plastic lamination and rinse well afterwards to prevent residue from getting on food.

Coffee Stains

* To remove a coffee stain from fabric or a rug, try one of these methods:
o Dip a white cloth into a beaten egg yolk and rub the yolk into the stain. Then rinse with clear water.
o Work denatured alcohol into the stain, then rinse with water.
o Apply a solution of 1/2 teaspoon mild detergent in a pint of water. Blot with a white towel. If the stain remains, apply a 50-50 solution of water and white vinegar and blot.

Glassware

* Use the bartender's method for speedy stemware washing. Holding the base, pump the glass vigorously in very hot sudsy water, then quickly put it in hot clear water (cooler water may shatter it) Dry upside down on a cotton towel.
* For extra-shiny, streakless glasses, add a little vinegar or borax to the final rinse water.
* If glasses have hard-water stains, rub them with a scouring pad dipped in vinegar.
* Never use hot water, harsh soaps, ammonia or washing soda on silver or gold-rimmed glasses.
* A well-lathered shaving brush cleans deeply etched or hobnailed glass especially well.
* If eggs have dried on your patterned glass tableware, rub off the residue with a slice of lemon.

Garbage Disposal Tips

* If you've ever switched on the garbage disposal instead of the kitchen light, mark the switch with a dab of red nail polish.
* If your dishwasher drains through your garbage disposal, switch it on when the hot soapy water is running through is so it gets a good cleaning.

Miscellaneous Jobs

* Stainless Steel - To remove water spots on stainless steel, rub area with a clean, soft cloth dampened with white vinegar. Then wipe dry to avoid spots.
* Heel Marks -Use a pencil eraser on black heel marks.
* Dishwasher Soap Film - Run a cup of white vinegar through the entire dishwashing cycle in an empty dishwasher to remove all soap film.
* Refrigerator Odors - A little vanilla poured on a piece of cotton and placed in the refrigerator will eliminate odors or after cleaning the refrigerator add a dash of lemon extract to the rinse water for a fresh scent.
* Stuck on Food - For stuck on food on a casserole dish, try adding 2 tablespoons of baking soda and boiling water to cover the stuck on food. Let sit for a while. The dish will be much easier to clean.

General Tips

* Keep an all-purpose cleaner and a sponge in the guest bath so you can sneak away and clean up when unexpected company shows up.
* Keep a squeegee in the shower so everyone can wipe it down when they are done.
* Disinfectant can be used on everything in the bath except the mirror.
* Don't forget doorknobs and switchplates.
* Clean after a steamy bath or shower. The walls, fixtures, etc., will be much easier to clean because the steam will have loosened the dirt.
* Wipe a stainless steel sink with vinegar or a touch of oil on a cloth to make the sink sparkle.

Cleaning Toilet Bowl

* Clean the toilet bowl while you're away by pouring in 1/4 cup bleach and leaving it until you return.
* Keep the toilet bowl ring-free by pouring a half-gallon of white vinegar in it once a month. Let it soak overnight before flushing.
* Don't use bleach if you're already using a tank-held cleaner that's released when the toilet is flushed. The two may react chemically.
* To avoid clogging and odors, pour one cup baking soda down the bowl weekly.

Air Freshener

* For immediate air freshener in the bath, place a fabric softener sheet in the wastepaper basket or add a dab of fragrance on a light bulb. When the light is on, the heat releases the aroma.
* To freshen drain, pour 1/4 to 1/2 box of baking soda down the drain, add 1/2 cup of white vinegar. Cover drain tightly for a few minutes and flush with cold water.

Shower Doors

* Rub glass shower doors with a white vinegar-dampened sponge to remove soap residue.
* To clean shower track door, pour full strength vinegar into the track, let soak for a few minutes, then rinse.
* A coat of acrylic floor finish gives new shine to fiberglass shower doors and makes water spots disappear. Club soda will give new shine to your counter tops.

Cleaning Shower Curtains

* Before hanging shower curtains, soak in salt water solutions to prevent mildew.
* To remove mildew, wash in hot soapy water, rub with lemon juice and let the shower curtain dry in the sun.
* For plastic curtains, clean with laundry pre-wash spray. Spray along the top, letting it run down to cover the curtain. Allow it to sit for a few minutes, then rinse it off.

SAFETY NOTE

• Safety rules must be taken into account when using cleaning machine and other electrical equipment.
• Wear appropriate particle dust mask during preparation and respirator during application.
• Wear safety bell when working overhead.
• Always read MSDS (material safety data sheet) for all chemicals before using.

I. PRECLEANING

Pre-cleaning, this as it implies, removes the gross contaminants before starting pure cleaning.
Rubbish such as debris, the piece of broken devices and other solids will be collected manually and bring to gathering point.
With furniture, use feather duster, towels or even vacuum to remove dust on its surface.

II. FINE CLEANING

Fine cleaning or pure cleaning is final step of cleaning process. Care must be taken into account during this step since you may damage cleaned objects if you are careless.

1. Cleaning glass

General note
• Never combine an acid and an alkali to clean glass. One partially neutralizes the other and you waste these neutralized materials. Thus do not mix vinegar and ammonia
• Do not drip alkaline or alcohol solutions on painted or varnished woodwork as it can damage the finish.
• Do not drip cleaning solution on woodwork.
• Avoid washing windows in direct sunlight because they tend to streak and are more difficult to clean.

Cleaning procedure
• Remove spot and the other stain such as dust, paint mark, grease… on glass surface and its frame by using specialized cleaning tools with dedicated chemicals solution such as ammonia, soda, alcohol…
• To remove hard water deposits and some soils, use a weak acid such as vinegar.
• Wring out a cloth, sponge, or chamois almost dry before wiping the glass surface. Dry the wet surface with paper towels, window wipes, or a chamois. Use rubber squeegees with long handles for large or high windows. When using a squeegee, stroke from top to bottom. Wipe the squeegee after each stroke.
• For glass which has had silver electro-deposited on the surface looks particularly unappealing when dirty, using liquid or cream silver-polish on a soft cloth and rubbing vigorously.

2. Cleaning sanitation areas

• Use brush and dedicated chemical solution to remove the spot and stain on all toilet parts (wall, lavabos, toilet seats, water taps….)
• Clean other equipments such as ventilation fans, hot water heaters…
• Clean lighting system such as light bulbs, light tubes…by using a clean cotton dust mop with Waterless Cleaner.
• Cleaning windows, window glass, doors… (see cleaning glass procedure)
• Use floor scraper, floor brush, wet mop and dedicated chemical solution to remove markings, stickers and other dirt such as soil, grease, gum …on floor. Using floor cleaning machine if needed.
• For the floor of toilet areas, see article (3): Cleaning and polishing floor

3. Cleaning carpet, furniture, partition

General note
• Keep windows and outside doors closed at all times during summer operations
• During unoccupied hours, turn exhaust fans off and close outside air dampers
• Keep lights on.
• Keep blinds open.
• Keep windows and doors closed.
• As a general note, carpets must be completely dry within 24 hours to ensure that mold growth does not occur.

Cleaning procedure
• Prepare Room:
Pick up all large objects such as crayons, paper, books, boxes, and other solid before vacuuming.
Use the vacuum to vacuum the area prior to cleaning. Assemble all the equipment and supplies and take them to the area to be cleaned.
• Vacuum carpet, furniture, partition
Go over entire carpet, furniture, partition with the vacuum cleaner to remove dirt, sand, and dust. This procedure requires the movement of all furniture including bookcases, cabinets, boxes, etc. in order to set up the room for cleaning.
• Remove gum and spots
Remove all gum and spots using gum removers and spot removers.
• Cut loose pile
Loose and frail carpet pile shall be cut to prevent the loose end from getting caught in the vacuum cleaner brush or the extractor machine therefore preventing damage to the carpet and to the equipment.
• Vacuum along baseboards and corners
Use a vacuum hose with crevice tool along the edge of the carpet and in corners where the upright vacuum cannot reach. Remove dirt, sand, dust and all foreign matter. Follow up with the upright vacuum.
• Pre-treat carpets
Using a pressure sprayer with a carpet cleaning solution, spray soiled areas such as doorways and traffic lanes before extracting. For very heavy soiled doorways, follow pre-treatment with one or two passes with the extractor machine to loosen dirt for normal cleaning.
• Extract carpets
With the extractor, floor machine, go over entire carpet to clean and remove dirt, soil, grime and stains. Repeat this process as needed in order to restore carpet to a sanitary condition keeping in mind not to go over wet carpet.
• Remove excess water from carpet
Extract as much water as possible using the extractor machine.
• Scrub along baseboards and corners
Use a wedge mop or brush dipped in a pail of diluted cleaner solution and clean along baseboards, corners and other areas where the extractor or floor machine cannot get to.
• Clean carpet doormats
Same with cleaning procedure as carpets, after cleaning, place mats on non-carpeted surface to dry. Do not put mats back on wet carpet floors.
• Turn on floor fans
Set up fans in rooms to assist with the drying process.
• Reset furniture
Put all furniture, cabinets, boxes, etc. back in their original position.

see Floor cleaning procedure on next post.

Source: PACO standard procedure,