advancing towards new frontiers allied ordnance of singapore wsh innovation awards 2008 -...
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Advancing Towards New FrontiersAllied Ordnance of Singapore
WSH Innovation Awards 2008 - Manufacturing
Presented by : Lim Siak Pin
Working At Height Solution For Gun Cupola
AOS 40mm/L70 Naval AOS 40mm/L70 Naval Air Defence Mount Air Defence Mount
(NADM) 330 (NADM) 330 Automatic GunAutomatic Gun
Advancing Towards New FrontiersAllied Ordnance of Singapore
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Team Name And Particulars
Team Leader: Lim Siak Pin (Engineer)
Members: Lee Cheng Mong (Engineer) Roslan Bin Mahmod (Snr. Technician) Tham Man Kwong (Snr. Technician) Jeyalingam Kumarasamy (Technician)
Safety Officer: Eric Law (Asst. Manager)
Facilitator: Leslie Lim (Asst. Vice President)
Team Formed: 20 Dec 2007
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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.
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Ministry of Manpower (MOM) Workplace Safety and Health Act (WSHA), Act 7 of 2006
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
– Fall arrest measures shall be implemented• Provision of secure foothold or handhold
• 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
0.7 m
3.7 m
Advancing Towards New FrontiersAllied Ordnance of Singapore
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
Advancing Towards New FrontiersAllied Ordnance of Singapore
Analytical Techniques
Severity Rating vs. Likelihood Rating
1 2 3Minor Moderate Severe
1 RemoteLow
2Low
3Medium
4
2 OccasionalLow
3Medium
4High
5
3 FrequentMedium
4High
5High
6
S: Severity (Injury / Property Damage)
LH
: Likelih
oo
d
Risk Level Estimator (E)
SP
Risk level score > 4 shall be regarded as significant risks, and shall be given priority in the risk control planning.
Advancing Towards New FrontiersAllied Ordnance of Singapore
Analytical Techniques
Severity Rating
Likelihood Rating
Score Definition
1 - MinorMinor 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.
Score Definition
1 - Remote Not likely to occur
2 - Occasional Possible or known to occur
3 - Frequent Common or repeating occurrence
Advancing Towards New FrontiersAllied Ordnance of Singapore
Analytical Techniques
Risk Levels
Advancing Towards New FrontiersAllied Ordnance of Singapore
Analytical Techniques
HIRADC Results
1a. 1b. 1c. 1d. 1e. 2a. 2b. 2c.
1Installation of weather stirps *
Fall from top of Cupola
Physical Injuries
a)Put on Safety hardness and secure it at the cupola ladder b)Do not wear shoes or socks while working on top of the Cupola.(c)Always squat down while working on top of the Cupola.(d)Ensure the surface of the Cupola is free of grease and oil
3 Severe
2 Occasional
5 High
Hand slipped when tightening bolts and nuts. Hurt knuckles and fingers
Hand injuries (Cuts and Bruises)
a)Wear protective hand glove. b)Always use correct, good-fitting tools. c)Exert good control of arm force.
1 Minor
1 Remote
2 Low
Hit by falling objects during tightening of bolts and nuts
Physical Injuries
a)Wear safety helmets and safety shoes. 1 Minor
1 Remote
2 Low
2Conduct transmission accuracy test
*Fall from top of Cupola
Physical Injuries
a)Put on Safety hardness and secure it at the cupola ladder b)Do not wear shoes or socks while working on top of the Cupola.(c)Always squat down while working on top of the Cupola.(d)Ensure the surface of the Cupola is free of grease and oil
3 Severe
2 Occasional
5 High
Likelihood Risk Level
1. Hazard Identification 2. Risk Evaluation
No. Work Activity RoutineNon-
RoutinePotential Hazard
Possible Accident /
Existing Control Measure Severity
Advancing Towards New FrontiersAllied Ordnance of Singapore
Analytical Techniques
Cause & Effect Analysis (MUDA identified)
CostSecuring of Safety Line
Men Method to reach Top of Gun Cupola
Working on Top of Gun Cupola
Full Harness
FixtureSafety Belt
Cupola Ladder
Crane
Fixture
Falls & injuries- no safety line
Falls & injuries- with Safety Belt
Falls & injuries- with Full Harness
Scaffolding
Ladder
Forklift
Boom Lift
Advancing Towards New FrontiersAllied Ordnance of Singapore
Analytical Techniques
Comparison Table
Advancing Towards New FrontiersAllied Ordnance of Singapore
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
Securing safety harness to ladder
Advancing Towards New FrontiersAllied Ordnance of Singapore
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
Advancing Towards New FrontiersAllied Ordnance of Singapore
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
Advancing Towards New FrontiersAllied Ordnance of Singapore
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
Advancing Towards New FrontiersAllied Ordnance of Singapore
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
Advancing Towards New FrontiersAllied Ordnance of Singapore
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
Advancing Towards New FrontiersAllied Ordnance of Singapore
Results Achieved HIRADC after implementation
Advancing Towards New FrontiersAllied Ordnance of Singapore
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.
Advancing Towards New FrontiersAllied Ordnance of Singapore
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.
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Thank You