handrail welder's friend (hwf)
TRANSCRIPT
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HANDRAIL WELDER’S FRIEND (HWF)
Workplace Safety and Health Innovation Awards 2012
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• 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.
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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
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Project Background
Workers fabricating and welding the handrails by sitting on working tables
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Work Procedure before Improvement
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Fishbone Diagram
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Areas for Improvement
Provide safer working environment
Improve productivity
Reduce required working space
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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
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Implementation
Setup Welding
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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.
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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
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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
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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
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Intangible Results
• Safer & better working environment
• Increase confidence level of the workers
• Demonstrated that the commitment to safety is put into action
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Conclusion
Safety and health of the workers improved
Productivity of handrail increased
Working space reduced
Cost saving of $16,000 from each vessel