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Our Project – Modification of Wind Sock Structure 3 Sep 2007. Team Details. Team Name: Maintenance Team. Team Members: . Team Meetings. Project Schedule. Total 13 suggestions were contributed; only three were qualified to be safety & health related project.
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TeamDetails Team Name: Maintenance Team Team Members:
Total 13 suggestions were contributed; only three were qualified to be safety & health related project. Three suggestions or safety concerns were as follows: Problems/ Risks Involved When Changing of Wind Sock. Problems/ Risks Involved Using Emergency Chlorine Shut-Off Valve. Risks Involved Without Proper Access platform for operating valves Project Selection –Brainstorming Session
Risk Assessment – Before Implementation (MOM Risk Matrix) Most of the Hazards were Due to Crane Operation
Steps of Operation BEFORE Implementing Selected Solution. Implementation 6 Steps Step 4: Trial Lift (w/o load) Ensure all measures taken prior to actual lift Step 1: Preparation Prepare manpower, accessories and crane service. Step 2: Administration Apply permits (cold work, lifting, road closure permits). Conduct tool box briefing. Inform control/guard room. Validate document Step 5: Lifting and Change Wind Sock Commence lift and change wind sock Step 6. Completion Complete work and finish off all administrative work. Step 3: Site Inspection & LMRA Cordon off to prevent unnecessary entry. Conduct inspection with checklist Conduct LMRA (Last Minute Risk Assessment)
Location of Windsocks –Before Implementation Above Pipe Rack Blending Process Unit
High cost for labour 1 crane driver, 1 lifting sup, 1 rigger & 2 fitters Set-up of crane and prep for operation. Use of man-cage Long hours 5 wind sock locations. Manual handling (pull push stretching) Fatigue Apply PTW (crane, road clearance and lifting permit). Lifting gear failure Fall from height Potential crane topple Too many procedures to be adhered to. High cost for equipment Fear of working at edge of tank Use of crane Excessive coordination Barricading of road Crane failure Trip and fall Transport excessive tools and accessories to the tank top. Housekeeping Windy Vapour smell from the tank hatch Oil leak from crane Change of bearing Wind sock comes in different sizes Exhaust from crane Lightning risk Fall from height Analytical Techniques –Root Cause Analysis Man Machine Method Potential risks/problems when changing wind sock Materials Environment
To reduce all factors by 75% Analytical Techniques To reduce all problems by 75%
Proposal 1 - Telescopic Structure: Simple and effective idea Not practical; Corrodes easily and flimsy. Expose to inclement weather; possibility of the wind sock structure to topple. Expose to caught in between hazard while adjusting the telescopic pole Proposal 2 - Pulley System: Not effective. Design not suitable for strong wind condition. Rope can get entangled with wind sock and pulley. Pulley requires maintenance Proposal 3 - Two-Section Structure Safe, effective and strong Easy to implement. Minimum maintenance was required. Proposed Solutions
Safety and Health - 1 is high (high risk) and 10 is low (0 hazard) Installation Cost - 1 is high cost (>S$ 20, 000) and 10 is low cost (<S$ 1000) Cost savings - 1 is less savings (<S$ 1000) and 10 is high savings (>S$ 20, 000) Effectiveness and Efficiency - 1 is low (Less effective and efficient) and 10 is high (Very Less effective and efficient) Within Team Capability - 1 is low (take more than> 12 months to implement proposal & and 10 is high (take less than 3 months to implement proposal ) Selection Criteria Rating
Selection of Proposal. Based on the ranking score and comparison made in the evaluation of proposed solutions, the team selected the “Two Section Structure” solution. Management Presentation. Short presentation of the study was tabled for the management’s endorsement. Team was commended for its efforts and the proposed solution was endorsed for implementation. Finalizing Selection
From medium to low risk From medium to low risk Risk Assessment – After Implementation (MOM Risk Matrix) (MOM Risk Matrix)
Steps of Operation AFTER Implementing Selected Solution. Implementation 3 Steps Step 1: PreparationStandby man and spare wind sock Step 2: Administration Apply cold work permit only Conduct LMRA (Last Minute Risk Assessment) Step 3: Change wind sock Change wind sock • Reduce/less • Steps • Admin work • Coordination => Leads to reduction in time => Less exposure to HAZARDS
Re-Location of Windsocks –After Implementation For better accessibility and proper/stable platform Relocate all to Tank/Roof-Top.
Removing Securing Pin Replacing Wind Sock Fixing Back Wind Sock Structure Lowering Upper Section Illustration of ChangingWind Sock- After Implementation
Each location: S$600/-Structure” solution. Five Locations: One-time Cost of S$3,000/- only Total Cost forImplementation & Installation
Cost Savings Results Achieved –Tangible Results Annual Cost reduction by: 86%
Save Time Results Achieved –Tangible Results • Before implementation : • Operation used to take two to three hours per location • For five locations: Approx: 15hrs • After Implementation: • Operation now takes 30min per location • For five locations: Approx: 2.5Hrs Time reduction by (every year): 83% The above calculations are done according to yearly maintenance schedule. However, there are instances where ad-hoc maintenance may be required. Therefore, further reductions can be expected. Time Reduction by: 83%
Results Achieved –Intangible Results • Safe operation and very minimum hazard exposure. • Reduce work steps (no machinery used, less man/ materials utilized and minimum administration) • Increase productivity and morale of workers. • Enhance efficiency and maintenance effectiveness. • Less time waste (no need to wait for crane and applying permit) • No possibility of environmental issues. • Confidence in our team’s ability to address and overcome problems has been enhanced. • Teamwork, sense of team identity and team morale has improved.
4.5 4 3.5 3 2.5 2 1.5 1 0.5 0 Variation of ResultsBetween Results & Initial Target: Safety 5 Method Human Time Cost
Risk Reduction In Summary
Standardization Documentation • Management was kept abreast of the success. • Updated procedures. • Amended JSA was endorsed by the management • JSA maintained in accordance with WSH (Risk Assessment) Regulations.
Review & Sustenance Review for Future Improvement • No negative feedback but only positive on the implementation • Receptive to new ideas and future improvements • Continuous improvements to the existing projects Team’s Next Project. • Working on with the second project under the project prioritization; i.e “Problems/ Risks Involved Using Emergency Chlorine Shut-Off Valve”.
Review & Sustenance Self Examination. • Team made up of committed colleagues and contractors. • Great success of this project reflects on the positive participation and co-operation of the team members. • Project has given the team greater confidence and morale. • It has also revealed that with good team work and overwhelming management support anything can be achieved.
Conclusion • Infineum Maintenance Team has always believed in making our plant a safe working environment for our colleagues, contractors and visitors. • The Maintenance Team looks forward for more challenges and opportunity to enhance the safety and health in Infineum • Lastly, we all know that lifting equipment is the second highest contributor of workplace deaths in 2006 and it has always been in the area of safety concern. • Safety as a Culture in Infineum, we have taken steps to prevent such occurrences in the plant and at the same time contributing to a healthier nationwide safety statistics
