HANDRAIL WELDER’S FRIEND (HWF)

Workplace Safety and Health Innovation Awards 2012

• We design, supply and installation of marine accommodation which includes pre-fabricated cabin and toilet, insulation, wall and ceiling panel, flooring, handrail, furniture, sanitary, etc.

• We fabricate in the workshop before installation on board.

Project Team

Team Leader Kyaw Kyaw Lwin

Member John Lim

Member Evelyn Chua

Member Nguyen T.T. Hung

Member K. Meenakshi

Member P. Ramesh

Member Myo Zaw

Member Roy

Member Zar Ni Tun

Member Zaw Shin

Member Healine Pau

Facilitator Vincent Wong

Project Background

Workers fabricating and welding the handrails by sitting on working tables

Work Procedure before Improvement

Fishbone Diagram

Areas for Improvement

Provide safer working environment

Improve productivity

Reduce required working space

Recommended Solution: HANDRAIL WELDER’S FRIEND (HWF)

Rotatable

Welding points can be accessed from both sides HWF can be rotated every 45o for difficult corners

Adjustable height Worker can sit on a chair to weld HWF is lightweight and compact

Implementation

Setup Welding

Comprehensive Protection

Falling hazard eliminated ; bodily injuries minimized

Ease of Set-up and Use

Setup time less than 15 minutes; the disassembly and reassembly of the handrail to the working tables are no longer necessary

Expandability

Applicable for fabrication of different sizes of staircase handrails (in same pattern)

Life Cycle Cost

Low material cost – built of mild steel; Low maintenance cost – painted steel minimized corrosion, minor maintenance required for painting.

HWF can last for 5 years with proper maintenance.

Risk Assessment Before Implementation 1. HAZARD IDENTICIFATION 2. RISK EVALUATION

No. Work Activity Hazard Possible Accident / Ill

Health Existing Risk Control

Se

ve

rity

Lik

eli

ho

od

Ris

k L

eve

l

1 Setting up of

working table

Awkward posture Back injuries NIL 2

3

Me

diu

m

Sharp object from

drilling tools Hand injuries / cuts

Use PPE

Check equipment

before use

1

3

Lo

w

2

Arrange / fit

stainless steel

pipes on the

working table

Sharp object Hand injuries / cuts Use PPE 1

3

Lo

w

Awkward posture Back injuries / neck

injuries NIL 1

3

Me

diu

m

3 Weld handrail

Falling from height Bodily injuries Supervisor to standby a

worker to oversee the work

3

3

Hig

h

Awkward posture Back injuries / health

problems

Rotate the worker, take

interval break after 15-30

minutes

2

3

Me

diu

m

Risk Assessment After Implementation 1. HAZARD IDENTICIFATION 2. RISK EVALUATION

No. Work Activity Hazard

Possible

Accident / Ill

Health

Existing Risk Control

Se

ve

rity

Lik

eli

ho

od

Ris

k L

eve

l

1

Arrange & fit

stainless steel

pipes on HWF

Sharp object Hand injuries /

cuts Use PPE 1

3

Lo

w

Awkward

posture

Back injuries /

neck injuries

HWF can be rotated and height

adjustable to fit the workers’

height while performing the task

1

1

Lo

w

2 Weld handrail Awkward

posture

Back injuries /

health problems

Welders are sitting on a chair to

perform the task.

Welders were briefed and trained

on correct sitting posture

1

2

Lo

w

Tangible Results

Working Table Handrail Welder’s Friend

Risk of falling from height High risk Risk eliminated

Risk of back injuries Medium risk Low risk

Productivity of each section

Low High

• Required working days 4 days 2 days

• Required manpower 3 men 2 men

• Required man hour 96 man-hours 32 man-hours

• Required working space 6m2 2m2

Cost saving of each vessel $0 S$16,000

Intangible Results

• Safer & better working environment

• Increase confidence level of the workers

• Demonstrated that the commitment to safety is put into action

Conclusion

Safety and health of the workers improved

Productivity of handrail increased

Working space reduced

Cost saving of $16,000 from each vessel