Transcript Venture Kaizen 08 - Singapore Manufacturing Federation

ST Engineering
EHS Award 2008 Safety
Improved Process for
Assembly of Rebound
Stopper For Bronco
Vehicle
TEAM (EA MOBILITY)
LEADER:
Phang Seng Keong (Process Engineer)
MEMBERS:
Leonard Lee (Process Engineer)
Willy Goh Beng Lip (Process Engineer)
Francis Sim Mong (Process Engineer)
B Thritraj (Senior Foreman)
Lim Hock Beng (Senior Technician)
Facilitator :
Geoy Meng Chye (Process Engineer)
Safety Advisor :
Michael Leong
Kinetics Integrated Manufacturing
SAFETY PROJECT
Improved Process for
Rebound Stopper Assembly
For Bronco
Kinetics Integrated Manufacturing
INTRODUCTION
• Kinetics Integrated Manufacturing is a Business Unit within ST Kinetics,
primarily responsible for manufacturing weapons and platform solutions.
• Mobility Systems (MS) Operations, Manufacturing Engineering (ME)
Department is primarily responsible to ensure transfer of engineering
designs to workshops, by designing the manufacturing process and required
supporting elements.
Kinetics Integrated Manufacturing
INTRODUCTION
• The Bronco vehicle is one of the most successful products from ST Kinetics,
producing in large quantities.
• During the annual HIRARC review, it was noted that for the Flatbed variant,
the process posed a hazard to the 4 crewmen involved.
(image of flatbed variant)
Kinetics Integrated Manufacturing
CURRENT SITUATION
Dead weight
Rebound Stopper
Idler Wheel
A 3- Ton weight is being use
to compress and open up the
last wheel to install the
rebound stopper.
Accident happen if there is no proper co-ordination.
Eg. Crushing of hands and fingers.
Kinetics Integrated Manufacturing
CURRENT SITUATION
1
4
The Bumper Stopper is
then mounted
Track are slipped onto
the track beam
2
The flatbed is lifted and
the aluminium block is
positioned under the idler
wheel
3
The external weight is
lifted and lowered to
stretched the idler wheel
Kinetics Integrated Manufacturing
Risk Assessment (Old)
Singapore Technologies Kinetics
Form M-EHS Chp 04-01 Rev 00
Kinetics Integrated Manufacturing
Hazard Identification, Risk Assessment and Risk Control (HIRARC) Worksheet
Dept/Location: Plant 1
Prepared By: Lee K.W.
Approved By: Phang S.K.
Date: 30th October 2007
Routine
Non-Routine
1
Lifting of Front
Cabin in order
to place
aluminium
block.
6
Y
N
2
Placement of
Aluminium
Block Under
the Rubber
Track.
6
Y
N
S/N
Assessment
of Activities /
Facilities
Hazards
Risk
Risk
Assessment
Rating
Rev No:
Identification No
/ Station
HIRARC No:
Risk Control Measures / SWP
Reference
Legal and
Other
Requirements
Improper rigging of hull
causing hull to drop.
P S E
1 3 3 Require 2 Crew to perform guide to
lifting & placement of hull.
Lifting of hull to place Improper rigging of hull
block.
causing hull to drop.
1 3 3 Require 2 Crew to perform guide to
lifting & placement of hull.
NA
Placement of
aluminium block
under rubber track.
1 3 3 Proper training & coordination for
crane operator and ground crew
NA
Lifting of hull.
Kinetics Integrated Manufacturing
Crushing of hand or
fingers due to poor
coordination.
NA
Risk Assessment (Old)
Singapore Technologies Kinetics
Form M-EHS Chp 04-01 Rev 00
Kinetics Integrated Manufacturing
Hazard Identification, Risk Assessment and Risk Control (HIRARC) Worksheet
Approved By: Phang S.K.
Date: 30th October 2007
1
Lifting of Rear
Cabin in order
to place
aluminium
block.
6
Y
N
2
Pitching of
Rear Cabin to
install stopper.
6
Y
N Activation of pitching
control.
3
Placement of
Aluminium
Block Under
the Rubber
Track.
6
Y
S/N
Assessment
of Activities /
Facilities
Hazards
Lifting of hull.
Risk
Improper rigging of hull
causing hull to drop.
Accidentally activate
steering thereby swing
rear cabin & hit crews.
N Lifting of hull to place Improper rigging of hull
block.
causing hull to drop.
Placement of
aluminium block
under rubber track.
Kinetics Integrated Manufacturing
Crushing of hand or
fingers due to poor
coordination.
Risk
Assessment
Rating
Prepared By: Lee K.W.
Non-Routine
Dept/Location: Plant 1
Routine
Rev No:
Identification No
/ Station
HIRARC No:
Risk Control Measures / SWP
Reference
P S E
1 3 3 Require 2 Crew to perform guide to
lifting & placement of hull.
Legal and
Other
Requirements
NA
1 3 3 Require close co-ordination
between crews.
NA
1 3 3 Require 2 Crew to perform guide to
lifting & placement of hull.
NA
1 3 3 Proper training & coordination for
crane operator and ground crew
NA
Risk Assessment (Old)
Singapore Technologies Kinetics
Form M-EHS Chp 04-01 Rev 00
Kinetics Integrated Manufacturing
1
Lifting of 3Ton weight
on Flatbed.
6
Y
N
Hazards
Aluminium
Block
Risk
P
Forklift to Lift Weight
Weight Dropping, poor
visual due to bulky item
Lifting of weight
Improper rigging of
weight causing weight to
drop
Improper sitting causing
of weight topple,
pinching of fingers
2
Placement of weight
on flat bed
2
Risk
Assessmen
t Rating
Routine
Assessment
of Activities /
Facilities
Identification No
/ Station
S/N
Non-Routine
Hazard Identification, Risk Assessment and Risk Control (HIRARC) Worksheet
Rev No: 001
Approved By: Phang S.K.
HIRARC No: M-HIRARC-XX-111
Prepared By: Lee K.W.
6
Y
N
Lifting of hull to place
block
Placement of block
Improper rigging of hull
causing hull to drop
Pinching of fingers due
to poor coordination
2
Probability (P)
P
1
2
3
Kinetics Integrated Manufacturing
2
2
Risk Control Measures /
SWP Reference
Legal and
Other
Requirements
E
Proper ground guide
NA
Proper training for rigging
NA
NA
3
3
2
2
3
Require 2 Crew to perform
guide to placement of
external weight
2
3
Require 2 Crew to perform
guide to placement of
NA
2
NA
3
Proper training &
coordination for crane
operator and ground crew
2
Risk Level Estimator (E)
Severity (S) (injury/property damage
S
1
2
3
Minor
Moderate
Severe
Trivial Risk
Tolerable Risk Moderate Risk
Rarely
1
2
3
Tolerable Risk Moderate Risk
Substantial
Likely
2
3
Risk 4
Moderate Risk
Substantial
Intolerable Risk
Frequent
3
Risk 4
5
S
Dept/Location: Plant 1
Date: 29th August 2007
2
Ideas on trial.
Brackets
Rotating the lead
screw will make
the bracket move
closer or further
apart
Road Wheel
Ideas on trial
• We had tried a pushing method, What it
meant was pushing the idler wheel
backwards
•The problem face, there wasn’t a fixed
position for us to push against. The road
wheels was being push forward.
Idler Wheel
Ideas on trial
• The idea came about why not pull.
•A 3 ton chain block was used.
•The setup is shown.
•It works but the track needed to be considered.
•NOW WE NEED A STRONG PULL FORCE.
Kinetics Integrated Manufacturing
Solution Criteria
Design Problem:
How to extend the track sufficiently to allow for space to in stall the
rebound stopper
Design Consideration
1. To move the last idler wheel by 16inch from the collapse position to the
extended position.
2. Upon stressing the torsion rubber, every degree we have an increase of
78kg. We require a force of 40000N (4000kg) to rotate to the correct
position of 52 degrees.
3. Availability of standard equipment to rotate the last road wheel : Chain
block 5tons, Wire rope winch 3.5tons and Hydraulic pull cylinder.
Design consideration
Description
Chain Block 3 tons
Chain Block 5 tons
Wire rope Winch 3.5tons
Pull Hydraulic cylinder
Hydraulic Jack
20kg
30kg
17kg
17kg
17kg
Dist to open
Weight
Space
Capacity
road wheel
Can be carried
Insuffcient Insufficient Sufficient
Too heavy to be carried Insuffcient Sufficient Sufficient
Can be carried
Sufficient Insufficient Sufficient
Can be carried
Sufficient Insufficient Insufficient
Can be carried
Sufficient Sufficient Sufficient
Kinetics Integrated Manufacturing
Remarks
Safety
good
good
good
good
good
Need to design a fixture
Design consideration
Description
Chain Block 3 tons
Chain Block 5 tons
20kg
30kg
Remarks
Dist to open
Weight
Space
Capacity
road wheel Safety
Can be carried
Insuffcient Insufficient Sufficient
good
Too heavy to be carried Insuffcient Sufficient Sufficient
good
3 ton chain block
• The chain block is insufficient to overcome the
40000N.
• This consideration was dropped
5 ton chain block
• The chain block can provide a 50000N force to
overcome the torsion rubber.
• Base on HFE, the recommended weight for 1
person to handle should be less then 20 kg. The
chain block weighs 30kg.
• There was space constraint between the track
beam and track
• This consideration was dropped
Kinetics Integrated Manufacturing
The chain block was the most obvious solution
to be tested. Unfortunately it came with serious
constraints that cannot be overlooked. Hence
the team proceeded to find other alternatives.
ur
Design consideration
Description
Wire rope Winch 3.5tons
17kg
Weight
Can be carried
Dist to open
Space
Capacity
road wheel Safety
Sufficient Insufficient Sufficient
good
3.5 ton wire rope winch
• The Winch was thin enough to fit into the space
constraint between the track beam and the
track.
• It serves the purpose of pulling action
• The Winch is insufficient to overcome the
40000N. There was no 5 ton and above winches
• This consideration was dropped
Kinetics Integrated Manufacturing
Remarks
Design consideration
Description
Pull Hydraulic cylinder
17kg
Weight
Can be carried
Dist to open
Space
Capacity
road wheel Safety
Sufficient Insufficient Insufficient good
Pull Hydraulic cylinder 3.5tons
• The Cylinder was compact enough to fit into the
space constraint between the track beam and
the track.
• It serves the purpose of pulling action
• The cylinder is insufficient to overcome the
40000N.
• This consideration was dropped
Kinetics Integrated Manufacturing
Remarks
Considerations
• There are no standard tooling or fixtures that is available in the
market to have a pulling force of more then 40000N
• The standard tooling or fixture should be lighter then 20kg and
compact in size
• And of course low in cost.
• Available standard parts are hydraulic cylinder which has a
rating of 10ton but they only come as push cylinder.
• The team had to iterate the pushing action of the hydraulic
cylinder to pulling action
Kinetics Integrated Manufacturing
Design consideration
Description
Hydraulic Jack
17kg
Weight
Can be carried
Remarks
Space
Capacity
Sufficient Sufficient
Dist to open
road wheel Safety
Sufficient
good
A fixture was needed
to reverse pushing to
a pulling
MS
SQ Hollow
63.5X63.5x6.35thk
From the last
proposed solution,
the team refined the
concept to come up
with an in-house
design.
Kinetics Integrated Manufacturing
Need to design a fixture
10ton
Hydraulic
Cylinder
Dia 25mm
Steel Shaft
Center Bar when
hydraulic jack is
extended will move to
the left
New Method Illustration
Straps attached to the
front bracket and rear
road wheel
A
Upon extending the jack the 2
bars A and B will move closer
together and thus pulling the
road wheel up
Kinetics Integrated Manufacturing
B
New Method Illustration
The jig being activated and the
last road wheel is pull to the
required gap to install the
Rebound Stopper.
Kinetics Integrated Manufacturing
Sequence of
installation
Kinetics Integrated Manufacturing
Enhance Safety For New Method
There were other safety consideration, There was a hazard that the cylinder will
fail and the idler wheel will swing back, This might happen when we are
installing the bumper stop.
Insert the 2 X M10 screws to its
mounting as shown to mitigate
the injuries if sling snaps and
road wheel swings down.
Primary safety feature:
Insertion of 2 x M10 screws will prevent any wrist injury
should the last road wheel swing down.
Kinetics Integrated Manufacturing
Enhance Safety For New Method
Place Rect-frame
at extension
square bracket.
Rectangular Frame
Secondary safety feature:
The rectangular frame to prevent the
separation of the 2 pulling belts at the
hydraulic fixture.
Kinetics Integrated Manufacturing
Enhance Safety For New Method
Place Pump Cover at
Hydraulic Air Pump
Added secondary safety feature:
The pump cover will prevent the worker hand
from accidentally activating the pump.
Kinetics Integrated Manufacturing
Hydraulic Air Pump
Evaluation of solution:
The new solution has been evaluated and the benefits are:
• The risks of human injury and property were found to have significantly
reduced compared to the earlier method when evaluated by the
HIRARC criteria.
• The crew size can be reduced from 4 to 2 thereby reducing risk
exposure.
• The space required has been reduce, hence reducing risk of affecting
adjacent workspace.
• The solution has been implemented for the remaining vehicles under
production. We have updated our work instructions with this process to
become SOP
Kinetics Integrated Manufacturing
Risk Assessment (New)
Singapore Technologies Kinetics
Form M-EHS Chp 04-01 Rev 00
Kinetics Integrated Manufacturing
Hazard Identification, Risk Assessment and Risk Control (HIRARC) Worksheet
Approved By: Phang S.K.
Date: 30th October 2007
S/N
1
Assessment
of Activities /
Facilities
Use of new
Fixture
6
Y
Hazards
N Placement of jig to
track beam
Risk
Pinching of
fingers
Risk
Assessment
Rating
Prepared By: Lee K.W.
Non-Routine
Dept/Location: Plant 1
Routine
Rev No:
Identification No
/ Station
HIRARC No:
P S E
1 1 1 Proper use of PPE
Rigging the straps to
fixture
Straps slipping 1 1 1
Pulling of rear road
wheel
Improper
coordination
between rigger
and
operator
Slipping
of of 1 1 1
hydraulic
cylinder
Accidental
1 1 1
release of
hydraulic jack
Accidentally
1 1 1
kick and
release cyl.
Hydraulic cylinder to
fixture.
Install of stopper
Hydraulic Air Pump
Kinetics Integrated Manufacturing
Risk Control Measures / SWP Reference
Legal and
Other
Requirements
NA
NA
Restraining plate is incorporated to the
fixture to prevent the straps from slipping.
1 1 1 Rigging and operator for cylinder to be the
same person
NA
Holders are incorporated to the fixture.
NA
Use enhance safty fixture like u-brkt to grip
hold of the the square hollow to prevent the
last road wheel from dropping .
NA
To place a cover over the pump.
NA
CONCLUSION
• Able to eliminate the risk of hand injuries through innovative
redesigning of the process
• Improve the safety environment for the operation crews.
• Team gained greater safety awareness and able to focus more on
safety aspects when designing processes in future.
Kinetics Integrated Manufacturing
Kinetics Integrated Manufacturing