ST Marine - Improvement Process For Vessel Windows Installation
Transcript of ST Marine - Improvement Process For Vessel Windows Installation
13th CONVENTION FOR WORKPLACE SAFETY AND
HEALTH INNOVATIONS IN MARINE INDUSTRY
IMPROVEMENT PROCESS FOR VESSEL WINDOWS
1
INSTALLATION
TEAM: ICE ST MARINE
IntroductionTeam Background
Initiative
We take initiative in identifying potential hazards, injuries and property
losses in the area of occupational safety and health.
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losses in the area of occupational safety and health.
Creative
We are creative in solving problems.
Effective
Forging ahead with innovative solutions, which are effective in creating a
safe work environment in fabrication workshops.
Introduction
Team Member
Leader Member Safety
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Our team, “ICE” was formed in July 2008 to focus on safety issues within the Hull fabrication process.
Li Da Hua
Snr Engineer (Process)
Logan Dhananjeyan
Chargehand (Hull)
Kyaw Thu Ya
Snr Safety Officer
Project Objective
• The main objectives of this project are to reduce the cycle
time and man-hour of window penetration installation
process and to eliminate all potential safety hazards.
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• Review the methodology of window installation on board
• Invent and fabricate a window installation fixture to meet the
same intent but at a more EFFECTIVE and most SAFE
manner.
Project Theme
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manner.
Project Selection & Definition
Acting
Force Stopper
Window
Two type of Window Installation
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Force Stopper
SupportZ
Y
X
Penetration installation
Project Selection & Definition
Where is the window installation?
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Window install on the side shell
Current Window Installation Method
Project Selection & Definition
• Positioning and tack welding of
Stopper
1
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• Positioning and tack welding of
stopper outside the opening.
• Transfer window in upright
position to installation site
• Positioning of support inside the
opening by means of tack welding.
2
3
Project Selection & Definition
Current Window Installation Method
4 5
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• Rigging of the window and placing it
upon the support
• Adjust window position and insert
window frame into the opening
Project Selection & Definition
Current Window Installation Method
6 7 8
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• Hammer the window frames into the opening with cushion from wooden
plank and ensure that the window frames are fully in contact with the
stoppers.
• Tack weld the window frames onto the side shell
• Remove stopper and support brackets
• Grind away the welding scar
No. Activity Hazard Hazard Effect S L Risk Level
1 Transfer of materials and tools Falling object Minor injury 3 1 4L
2 Positioning the stopper and supporter Falling object Major injury 3 3 6M
Burning by welding spark Major injury 3 2 5M
Contact with hot surface Major injury 3 1 4L
3 Transfer the window to installation location Injure by window fall Major injury 3 4 7H
Widow fall down and damage Major injury 3 4 7H
Hitting foot Minor injury 2 2 4L
4 Lift up the window and rest it on the supports Widow fall down and damage Major injury 3 4 7H
AnalysisRisk Assessment Before Improvement
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4 Lift up the window and rest it on the supports Widow fall down and damage Major injury 3 4 7H
Finger pinch Major Injury 3 3 6M
5 Adjusting the window and slot into opening Finger pinch Major Injury 3 3 6M
Strike by wooden stick Minor injury 3 4 7H
Contact with hot surface Major injury 3 1 4L
6 Tack weld window frame Expose to radiation Minor injury 2 2 4L
7 Remove stopper and supporter Struck by flying particle Minor injury 2 1 3L
Strike by hammer Minor injury 3 4 7H
Falling object Major injury 3 3 6M
Contact with hot surface Major injury 3 1 4L
8 Pickup grinding Hand cut by grinding disc Major injury 4 3 7H
Strike by flying particle Minor injury 2 1 3L
AnalysisRoot Cause Verifying
Injuries and
ManMaterial
Temporary support
Opening wrong size
Different sharp of window
Worker fatigue
Skill requirement
Workers’ carelessInexperience
Window heavy
Numbers of tools
Lack of instructions
Long fitting time
No pre-check
Lack of safety
awareness
No holding
window properly
Different thickness of side shell
Window is brittle
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Injuries and property damage incurred during window installation on board
Method Tools
Grinding disc fly out
Cut during grinding
Tools fall from height
Window is heavySkill requirement
for fitting
Too many tack
welding
Manual handling
window transferring
Grind welding scar
Long fitting time
Tack weld support
and stopper brackets
No proper equipment
Manual handling
window adjustment
Non clear Operation
procedure
No proper fixture
Lack of instruction
Support removalWear and tear
Poor maintenance
and no pre-check
Lack of instruction
InexperienceCareless
Numbers of tools
Strike by hammer
Burn by welding spark
Operation not
ergonomic
Project Selection & Definition
Root Causes
Risk Root Causes
� High risk of work related injury
� Hand/ finger/back - manual handling
� Eye - grinding and tack welding
operation
� Too many tools use for window
installation.
� No proper fixture use for manual
handling of heavy window.
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operation
� Body – work at high
� High risk of catching fire
� Sparks from heavy grinding
� Cutting and tack welding operation
� Window damage- transferring
handling of heavy window.
� Too much tack welding and pickup
grinding.
� No proper tools for window fitting and
support removal.
� Too many temporary support used.
Project Selection & Definition
Areas for Improvement
� Positioning and tack welding of stopper and support brackets.
� Transfer window to installation in upright position
� Rigging of window and placing it onto temporary support
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� Adjusting window frame position
� Hammering of window frame in position.
� Remove stopper and support brackets
� Pick up grinding
Analysis
Risk Control
Elimination
Substitution
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Engineering Control
Administration Control
PPE
Eliminate pick
up grinding
Reduce object
falling
possibility
Reduce the
number of
Eliminate finger
injuries
Eliminate strike
by hammer
Eliminate cut by
grinding disc
Reduce Window Installation Risk
Analysis
Solutions
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up grinding
Eliminate tack
welding
Fixture jig to replace
the stopper and
temporary support
plate
number of
objects (tools)
Fixture jig can
provide same
function as all the
tools
by hammer
Use different
alignment
method
New Fixture
Innovation & Implementation
Alternative Solution 1
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• Only can provide z-axis alignment. (up & down)
• Not accurate enough for alignment
• Installation at height is very difficult due to its heavy weight.
• Reduce tack welding and grinding job, but still need to install temporary
lifting eye lug.
Z
Y
X
Alternative Solution 2
Innovation & Implementation
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• Window clamping method is minimum, only suitable for particular size of circular
window installation.
• y-axis adjustment not accurate enough. (left & right)
• Not able to adjust in z –axis. (Up and down)
Z
Y
X
� Jig is able to apply force in 3 directions (x, y ,z axis), easily adjustment in 3 dimensions
� Jig is able to adapt to all type and size of window installation
Innovation & Implementation
Innovation Idea
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� No need to install the stopper and support on-site
� Able to proceed welding after fitting immediately
� Easy to transfer window
� Portable
� Easy design and user friendly
Jig Design
Window Installation Jig
Clamping Function
Design Concept
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Transfer Function
Adjustment Function
Jig Design
Design Concept
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Jig Design
Clamping System Design
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• Able to clamp various different shape of window
• Able to clamp different size of window
• Provide a upright clamping position
Jig Design
Clamping System Design
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• When jack piston extends, a force is applied on the stationary
frame, which is fixed onto the main frame. As a result, the top
adjustable clamp moves downward, thus providing a downward
force on the object.
• This clamping force prevents the window frame from tilting.
Jig Design
Clamping System Design
Jack released at low
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Jack released at low
position
• The purpose of the springs is to prevent the jack from falling before clamping
commence.
• To allow fast restoration of the top adjustable frame after the jacking force is released.
Jack extend at high position
Jig Design
Clamping System Design
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• The height of stationary frame is able to be adjust to height of the installing
window by various locations.
• Adjustable position of the top clamp point.
Jig Design
Clamping System Design
The clamp point
surface with texture
to maximize contact
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•The bottom two clamp points are able to rotate in all required angle so that it
can accommodate different outer profiles of window.
•The position of bottom clamp point is able to be adjust depend on the width of
the window (X-axis)
Jig Design
Clamping System Design
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Circle Window Clamping points
Rectangular Window Clamping points
Jig Design
Adjusting System Design
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Jig Design
Adjusting System Design
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• Assembly of two adjusting tables, to provide adjusting movement in x and y axis
Jig Design
Transfer System Design
Release
Break
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It is a 1.5 ton scissor table with 4 lockable wheels
Maximum lifting high is 1.2m
WheelsPedal
Jig Design
Transfer System Design
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Counter weight will increase the balance and
prevent jig fall down during window
transferring
Jig Design
Transfer System Design
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• Four lifting eye lugs are installed at four
corners of the jig.
• The clamping system is collapsible
during transportation, the CG will be lower
down in order to reduce the risk of lifting
hazard.
Process after Improvement
1 2
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Clamp the window on the fixture Transfer window to installation location
Allow the fixture is parallel to the side
shell
Lock 4 wheels
3 4
Process after Improvement
5 6
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Jack up to the installation level z-axis Adjustment in x and y axis
Window slot in to the opening
7
Process after Improvement
8 9
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Tack weld the window frame on the side
shell
Release the jack and remove the fixture
Results Achievement
No Activities Hazards Hazard effect S L Risk Level
1 Clamp the window on jig Injury by window fall down Major injury 3 1 4L
Window fall down and damage Major injury 3 1 4L
2 Transfer window to installation location Jig trap and fall down Major injury 3 1 3L
3Installation setup. ( fixture parallel to side
shell, lock wheels)
Unsafe practiceMinor injury 2 2 4L
4 Adjustment in x, y and z axis Unsafe practice Minor injury 1 1 2L
Risk Assessment after Improvement
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4 Adjustment in x, y and z axis Unsafe practice Minor injury 1 1 2L
5 Slot in the window Window frame surface scratch Minor 1 1 2L
6 Tack weld the window frame on the side shell Expose to radiation Minor injury 2 2 4L
7 Release jack and remove jig Finger pinch Minor injury 3 1 4L
Results Achievement
Risk Level Comparison
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Results Achievement
Before Improvement After Improvement
1. The average risk level of window
installation on board is medium to
high level
1. The average risk level of window
installation on board is improved to low level
2. 5 reported accidents from year 06 - 09 2. No reported accident till now after
implementation
Tangible Benefits
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implementation
3. Hull fitting window installation are
carried out 4 or more employees
3. Window installation can be carried out by
one employee
4. Inserts and penetration installation
with manually handling.
4. This invention is also applicable for
installation of inserts and penetrations on
board, e.g. louvers and coaming
Intangible Benefits
� Reduce risk of hand injury during window installation onboard.
� Eliminate any injury caused by using grinder or performing welding
operations.
� Increase work productivity, create more job satisfaction.
Results Achievement
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� Increase work productivity, create more job satisfaction.
� Improve workers’ skill level through the integration of One-Man-
Operations concept.
� This major outward change in hull fitting process continues to
emphasis to employees on the importance of a strong safety culture
through continuous improvements.
Standardization
� The new process has been approved by management and implemented.
� The new process has been standardized and documented in Standard
Working Procedure.
� The training session has been conducted, and the workers have been
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� The training session has been conducted, and the workers have been
briefed and evaluated on safe use of this window installation jig.
� The qualified workers have been granted by OMO training certification.
� The jig has been fabricated and equipped to window installation teams.
Review & Sustenance
Further Improvement
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The clamping system is able to face in different direction to suitable able
in variable installation situation.
Review & Sustenance
Further Improvement
Turnbuckle retreat
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Turnbuckle extend
• The adjusting system is able to provide a incline stance
• Suitable for incline side shell window installation
Review & Sustenance
Further Improvement
- 20 degree +20 degree
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It is able to provide ±20 degree incline
Review & Sustenance
Further Improvement
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Plumb-line for incline degree measurement
Review & Sustenance
The team’s next project will focus on hull block assembly fitting process. It
causes most manual handling hazard in the ship yard workshop.
Team’s Next Project
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� The current window installation process eliminates the risk of hot work through the use of a unique jig.
� The design of this jig provides the platform to reduce the risk of hand related injuries during the fitting of window installation onboard.
Conclusion
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� The jig has been fabricated and equipped to window installation team.
� To date, it has proven to be a well designed jig with no safety issue.
� The invention of this jig has help to reduce injuries and raised the morale of the employees.
Thank You
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Question & Answer