Transcript Document

WSH Innovation Awards
2008 - Manufacturing
Allied Ordnance of Singapore
Advancing Towards New Frontiers
Presented by : Lim Siak Pin
Working At Height
Solution For Gun Cupola
AOS 40mm/L70 Naval
Air Defence Mount
(NADM) 330
Automatic Gun
Team Name And Particulars

Team Leader:
Lim Siak Pin
(Engineer)

Members:
Lee Cheng Mong
Roslan Bin Mahmod
Tham Man Kwong
Jeyalingam Kumarasamy
(Engineer)
(Snr. Technician)
(Snr. Technician)
(Technician)

Safety Officer:
Eric Law
(Asst. Manager)

Facilitator:
Leslie Lim
(Asst. Vice President)

Team Formed:
20 Dec 2007
Allied Ordnance of Singapore
Advancing Towards New Frontiers
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Background
 Allied Ordnance of Singapore (Pte) Ltd focuses on
2 core business areas:
– Servicing of gunnery and torpedo launcher weapon systems
– Export sales of the NADM and FADM guns
 Scope of work for AOS 40mm / L70 NADM 330
production includes:
–
–
–
–
Assembly
Testing
Quality Control
Firing Acceptance
 High risk factors associated with working at height
was identified - This could lead to serious injuries
or possibly, permanent disabilities.
Allied Ordnance of Singapore
Advancing Towards New Frontiers
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Project Selection And Definition
 Project Theme
– Working at height solution for gun cupola
 Problem
– When the technicians are working on top of the
Cupola, there is a high risk hazard of falling from
height
3.7 m
– Fall arrest measures shall be implemented
• Provision of secure foothold or handhold
0.7 m
• Provision of safety harness or safety belt
• Provision of anchor point is required if the use of
safety harness is necessary
Height from ground to top of Gun Cupola
Ministry of Manpower (MOM) Workplace Safety and Health Act (WSHA), Act 7 of 2006
Allied Ordnance of Singapore
Advancing Towards New Frontiers
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Project Selection And Definition
 Identification of Risk Hazards
– Application of Hazard Identification, Risk Assessment and Determining Control
(HIRADC)
(Reference: DT-STK-EHSM-02 Chap 04 Rev 00 2008-03-27rev and S-HIRADC-AOS-064)
 Risk evaluation based on the following steps:
– Use Severity Rating to determine severity rate associated with risks
– Use Likelihood Rating to determine probability of risk occurring
– Use Risk Level Estimator to assess risk level
• Based on severity & likelihood
 Focuses on 2 work scenario
– Installation of weather strips
– Conducting of transmission accuracy test
Allied Ordnance of Singapore
Advancing Towards New Frontiers
Analytical Techniques
 Severity Rating vs. Likelihood Rating
Risk Level Estimator (E)
LH: Likelihood
P
1
2
3
S: Severity (Injury / Property Damage)
1
2
3
S
Minor
Moderate
Severe
Low
Low
Medium
Remote
2
3
4
Low
Medium
High
Occasional
3
4
5
Medium
High
High
Frequent
4
5
6
Risk level score > 4 shall be regarded as significant risks, and shall be given priority in the risk control planning.
Allied Ordnance of Singapore
Advancing Towards New Frontiers
Analytical Techniques
 Severity Rating
Score
Definition
1 - Minor
Minor injury or illness, first aid treatment given.
No loss time due to injury
2 - Moderate
Loss time due to injury or illness not exceeding 3 days.
3 - Severe
Loss time due to injury or illness exceeding 3 days.
Permanent disability or death.
 Likelihood Rating
Score
Definition
1 - Remote
Not likely to occur
2 - Occasional
Possible or known to occur
3 - Frequent
Common or repeating occurrence
Allied Ordnance of Singapore
Advancing Towards New Frontiers
Analytical Techniques
 Risk Levels
Risk Level
Acceptability of Risk
Low Risk
Acceptable
Medium Risk
Moderately acceptable
High Risk
Not acceptable
Allied Ordnance of Singapore
Recommended Action
No additional risk control measures may be needed.
However, frequent review may be needed to ensure that risk
level assigned is accurate and does not increase over time.
A careful evaluation of the hazards should be carried out to
ensure that the risk level is reduced to as low as is
practicable within a defined time period. Interim risk control
measures, such as administrative controls, may be
implemented. Management attention is required.
High Risk level must be reduced to at least Medium risk
before work commences. There should not any interim risk
control measures and risk control measures should not be
overly dependent on personal protective equipment or
appliances. If need be, the hazard should be eliminated
before work commences.
Immediate management intervention is required before work
commences.
Advancing Towards New Frontiers
Analytical Techniques
 HIRADC Results
1. Hazard Identification
1a.
1b.
1c.
NonNo. Work Activity Routine
Potential Hazard
Routine
1
2
Installation of
weather stirps
Conduct
transmission
accuracy test
*
*
1d.
Possible
Accident /
2. Risk Evaluation
1e.
2a.
2b.
2c.
Existing Control Measure
Severity
Likelihood
Risk Level
3
Severe
2
Occasional
5
High
1
Minor
1
Remote
2
Low
1
Minor
1
Remote
2
Low
3
Severe
2
Occasional
5
High
a)Put on Safety hardness and secure it at the
cupola ladder
b)Do not wear shoes or socks while working
Fall from top of
Physical
on top of the Cupola.
Cupola
Injuries
(c)Always squat down while working on top of
the Cupola.
(d)Ensure the surface of the Cupola is free of
grease and oil
Hand slipped when
a)Wear protective hand glove.
Hand injuries
tightening bolts and
b)Always use correct, good-fitting tools.
(Cuts and
nuts. Hurt knuckles
c)Exert good control of arm force.
Bruises)
and fingers
Hit by falling objects
Physical
during tightening of
a)Wear safety helmets and safety shoes.
Injuries
bolts and nuts
a)Put on Safety hardness and secure it at the
cupola ladder
b)Do not wear shoes or socks while working
Fall from top of
Physical
on top of the Cupola.
Cupola
Injuries
(c)Always squat down while working on top of
the Cupola.
(d)Ensure the surface of the Cupola is free of
grease and oil
Allied Ordnance of Singapore
Advancing Towards New Frontiers
Analytical Techniques
 Cause & Effect Analysis (MUDA identified)
Securing of
Safety Line
Cost
Full Harness
Crane
Safety Belt
Fixture
Cupola Ladder
Fixture
Falls & injuries
- no safety line
Falls & injuries
- with Full Harness
Scaffolding
Falls & injuries
- with Safety Belt
Working on Top
of Gun Cupola
Ladder
Forklift
Boom Lift
Men
Allied Ordnance of Singapore
Method to reach
Top of Gun Cupola
Advancing Towards New Frontiers
Analytical Techniques
 Comparison Table
MUDA
Method to
reach Cupola
top
Cost
Causes
Possible Solution
Advantage
Disadvantage
Crane
Fast
Unsafe & not allow
Scaffolding
Hook on the safety
harness to hoist
you up
Lift you up
Safe
Space constrain & expensive
Forklift
Lift you up
Fast
Unsafe & not allow
Ladder
Climb up
Easy & fast
Falling Hazard at Moderate level
Boom lift
Lift you up
Fast
Space constrain & expensive
Full harness
Purchase
Purchase
Safe & MOM Requirement
Safe & Cheaper
Incur cost
MOM not allow
Design & fabricate
Secure at the crane
hook
Secure at the
ladder
Secure at the
fixture
Safe & additional protection
Easy & fast.
No much movement restrictions
Easy and no cost
Fabricate & Expensive
Falling Hazard at risk level
Safety belt
Fixture
Crane
Cupola ladder
Securing of
Safety Line
Men
Fixture
Fall & injured
No safety line
Fall & injured
With safety belt
Fall & injured
with full harness
Allied Ordnance of Singapore
Use safety line
Secure at fixture
Additional Safety
Secure at fixture
Additional Safety
Easy and No movement
restriction
Additional risk control
& minimise falling hazard
Not much movement restriction
Not much movement restrictions &
minimize falling hazard
Not much movement
restrictions & minimize falling
hazard
Restrictions movement &
Falling Hazard at risk level
Need to fabricate and incurs cost
Falling Hazard at likelihood risk level
Falling Hazard at Moderate level
Falling Hazard at Moderate level
Advancing Towards New Frontiers
Project Selection & Definition
 Problems
– Sloping surface
– Securing safety harness at ladder located on side
of cupola
• Restricts body movements
– No handgrip available
– Not possible to install working platform
• When mounted on-board ship
 Current Method
– Insufficient protection
– Restricted body movements
– Potential falling hazard @ high risk level
Allied Ordnance of Singapore
Securing safety harness to ladder
Advancing Towards New Frontiers
Corrective Action & Implementation
 Solution
– Design a fixture that can be secured on the top of
the cupola
– Fixture will act as an anchor point
– Safety harness can then be secured to this fixture
– Prevent falls from height
– Fixture can be used as fencing and handgrip.
Fixture Design
Allied Ordnance of Singapore
Advancing Towards New Frontiers
Corrective Action & Implementation
 Fixture Specifications
– Aluminium alloy fixture
– Safe Working Load (SWL) = max 100kg
– Load test carried out by approved test body
• Singapore Test Service Pte Ltd
– Certified and examined by a Professional
Engineer
• Casy Consultancy Services
Allied Ordnance of Singapore
Advancing Towards New Frontiers
Corrective Action & Implementation
 Securing of Fixture
– On top of gun cupola
– Secured on the mounting points with bolts and nuts
 Advantages
–
–
–
–
–
–
–
Act as a fencing
Act as a handgrip
Does not cause restrictions to body movements
Secured on the existing mounting points
No drilling required
Fast installation & removal
Light weight
Allied Ordnance of Singapore
Advancing Towards New Frontiers
Corrective Action & Implementation
 Standardisation
– Safe Work Procedure (S-SWP-AOS-064) document have been put up
– Production team briefed
• Risk control measures
• Safe Work Procedure for the new fixture
– Fixture registered under list of lifting equipment and accessories
– Yearly inspection conducted by Approved Professional Engineer
Allied Ordnance of Singapore
Advancing Towards New Frontiers
Results Achieved
 High Workers Confidence and Morale
– Assured of safety
– Focus on work rather than fall
 Results
– Increased productivity
– Improved efficiency
– Improved HIRADC results
• Reduced from high to Low Risk level
Fixture was implemented with Immediate Effect
Allied Ordnance of Singapore
Advancing Towards New Frontiers
Results Achieved
 HIRADC after implementation
1. Hazard Identification
1a.
1b.
1c.
NonNo. Work Activity Routine
Potential Hazard
Routine
1
2
Installation of
weather stirps
Conduct
transmission
accuracy test
*
*
Allied Ordnance of Singapore
1d.
Possible
Accident /
2. Risk Evaluation
1e.
2a.
Existing Control Measure
Severity
(a)Secure the Aluminum alloy fixture on top
the gun cupola.
(b)Put on Safety hardness and secure it onto
this fixture for greater mobility
Fall from top of
Physical
(c)Do not wear shoes or socks while working
Cupola
Injuries
on top of the Cupola.
(d)Always squat down while working on top of
the Cupola.
(e)Ensure the surface of the Cupola is free of
grease and oil.
Hand slipped when
a)Wear protective hand glove.
Hand injuries
tightening bolts and
b)Always use correct, good-fitting tools.
(Cuts and
nuts. Hurt knuckles
c)Exert good control of arm force.
Bruises)
and fingers
Hit by falling objects
Physical
during tightening of
a)Wear safety helmets and safety shoes.
Injuries
bolts and nuts
(a)Secure the Aluminum alloy fixture on top
the gun cupola.
(b)Put on Safety hardness and secure it onto
this fixture for greater mobility
Fall from top of
Physical
(c)Do not wear shoes or socks while working
Cupola
Injuries
on top of the Cupola.
(d)Always squat down while working on top of
the Cupola.
(e)Ensure the surface of the Cupola is free of
grease and oil.
2b.
2c.
Likelihood Risk Level
2
Moderate
1
Remote
3
Low
1
Minor
1
Remote
2
Low
1
Minor
1
Remote
2
Low
2
Moderate
1
Remote
3
Low
Advancing Towards New Frontiers
Review & Sustenance
 Feedback will be gathered on this implementation
 HIRADC worksheets will be reviewed @ end 2008
 HIRADC worksheets together with the risk control plan and related SWP shall be reviewed
for adequacy and effectiveness at least once in 3 year
WAY AHEAD
Our Next Project is to tackle/review the falling hazard for covering the gun
with tarpaulin prior to transportation.
Allied Ordnance of Singapore
Advancing Towards New Frontiers
Conclusion
 The production team had not only successfully delivered quality products to our satisfied
customers, the display of the teams’ exemplary safety conscious attitude through
actively identifying risks and/or safety hazards and implementation of control measures must
be strongly commended.
 The team had maintained an excellent track record of zero accident and had also
pro-actively identified risks and/or safety hazards encountered during their course of work.
With the installation of the aluminium alloy fixture, it would eliminate the high risks of falling
from height and prevent any unnecessary mishaps to happen.
Allied Ordnance of Singapore
Advancing Towards New Frontiers
Thank You
Allied Ordnance of Singapore
Advancing Towards New Frontiers
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