advancing towards new frontiers allied ordnance of singapore wsh innovation awards 2008 -...

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


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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


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


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.



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



Risk Levels



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



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



Comparison Table


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


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



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



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



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


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


Results Achieved HIRADC after implementation


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.


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

advancing towards new frontiers allied ordnance of singapore wsh innovation awards 2008 -...

Documents

risk assessment

risk evaluation

risk control planning

high risk hazard

use severity rating

severity rate

severity likelihoodfocuses

use of safety harness