Premier Foods

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• PREMIER FOODS FIRE LOSS
October 2004
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1. History
2. Cause
3. Loss analysis
4. Loss lessons
5. Premier Foods Risk Management
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2003
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two separate ex-warehouses
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construction
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non-combustible
all new projects using PIR or Rockwool
protection
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4,940m² Pickles factory
4,500m² Sauces factory
limited AFA / AFD
20/5 occupancy
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Canopy Project
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The Fire
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The Aftermath
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The Aftermath
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Forensic Examination
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Eye-witness statements
Fire brigade incident report
CCTV footage
Examination of the initial ignition area
Simulated fire test
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Favourable factors
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Non-combustible construction
Polycarbonate roof lights
Use of approved panels
Employee training in the use of
extinguishers
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Fire brigade response time
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Favourable Factors
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fire brigade response time
01:43 – time of call
01:48 – first pump arrives on site
01:50 – 4x make up pumps + ladder
02:00 – 6x make up pumps arrive
02:45 – aerial ladder from Colchester
03:02 – 5x make up pumps arrive
03:36 – 5x make up pumps arrive
04:14 – 5x make up pumps arrive
05:00 – fire controlled
25 MP and >150 fire fighters
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Unfavourable Factors
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Creation of the single fire area
Lack of detection in the new canopy
Water supplies insufficient for size of
fire
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Halogen lamps in storage areas
Combustible storage next to buildings
Sole production site with no back up
Asbestos present in several areas
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Loss Analysis
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PD/BI >£30m
Damage to packing
lines
Damage to building
Loss of main utility
feeds
Peak season
Supplier bottlenecks
Outsourcing hurdles
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Complications
Asbestos contamination
Fire safety issues
Denial of access
PD/BI and PL conflicts
Policy issues
Brand damage
Marketing requirements
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Management of Change
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CHANGE
Construct a canopy between
two buildings
Install temporary Halogen
lights
Peak Season Storage
Peak season Working
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CONSEQUENCE
Create a single Fire Area
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Increased Risk to stock under
canopy
Increased Production
Increased Stock
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Stock stored too high
Main SON lamps turned off
Halogen lamps turned on and left on
Lamps ignited stock
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Recovery
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Pickles production restored within 2 weeks
Product packaged off-site
Competitor resources being used
Sauces production restored at reduced
capacity
Roof to be replaced progressively
Temporary boilers on site
Leased office space found and occupied
PR exercise supported by adjusters
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Summary
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Totally preventable
Failure to manage change effectively
Failure to install detection
Failure to cope with peak storage demands
Reliance on Fire Brigade capabilities
Reliance on a single production site
Construction saved £millions in BI
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Planning / Improvement
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Procedures onto Lotus Notes
Property Loss Manual, parts of which are to be incorporated into the
Engineering Standards.
Coordinated Business Continuity Plans, Ambient now the priority area,
Mills and Bakeries have fallback plans in place.
Hazard identification part of TOPS tours, over 20000 hazards identified
and 17000 actions completed in the year.
Objective setting particularly for response rates and completion of
Human Element and Management issues, included in Service Level
Agreements.
Emergency Procedures for each site amalgamated with Fire Safety
logbooks for the Fire Safety Order.
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Measure & Target
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Coordinated spreadsheet of completion and responses for every site to
be available through Lotus Notes.
Monthly updates required for each site
Monthly collated property loss reports
Published Premier Foods figures monthly
Cross Checks
Completion rates graphs
Capex expended and planned
Formalised Fire Investigation reports
Health, Safety and Fire Audits.
Ad hoc audits on system for identified risk areas eg Contractors, Hot
Work etc.
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Property Loss Standards
Corporate Standards
For
Property Loss Control
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Revised document is now on
Lotus Notes replacing the
previous RHM one.
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New version includes:
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Project Checklists which are now
part of the Capex applications
Site Closure documentation
Management of Vacant sites
procedure.
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Hyperlinks from the index page to
the relevant sections.
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New oven risk assessment added
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CrossCheck
Ovens
Deadline: 27th
May, 2008
CROSSCHECK
No
Ovens - Checklist
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How often are the ovens cleaned?
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Are there inspections between cleans, if so how often?
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Has the inspection information been used in determining the cleaning
frequencies?
How often is the full ductwork inspected?
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How often is it cleaned?
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Has the inspection information been used to determine cleaning
frequencies?
Are there capex projects recently completed, in hand or proposed that will
assist in reducing waste in the oven, assist cleaning or suppress fires
should they occur? Please give details below
Similarly are there revenue initiatives for the above? Please give details
below.
Are there procedures in place when there are major changes to oven
operating conditions or products produced? (It would assist if example of
these procedures were attached to this Cross check return)
Are records available for all of the above?
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Where are they stored?
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How frequently are they audited apart from Insurance company visits?
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Are there areas of the oven which are inaccessible for regular cleaning?
If so please details below .
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Are there direct acting alarms/links for isolating the main heat source on
the oven in the event of a fire e.g. thermal links directly connected to a gas
valve?
Are these regularly checked for correct operation and recorded as such?
If a fire suppression system is fitted, e.g. water mist, does it interrupt the
fuel supply of the heat source for the oven?
Are these regularly checked for correct operation and recorded as such?
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Actions arising are to include: those completed and still outstanding, person responsible and expected
completion date.
Checklist Completed By:
Signed:
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Date: _______
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Wellingborough
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Ashford
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Knighton
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Mills
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