Jurong Shipyard Pte Ltd- Innovative Hydraulic Cable Drum Jack
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Transcript of Jurong Shipyard Pte Ltd- Innovative Hydraulic Cable Drum Jack
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Jurong Electrical Automation Jurong Shipyard Pte. Ltd. 29, Tanjong Kling Road Singapore 628054
1. INTRODUCTION
a) Team’s Background and Objectives
We are team SPOT from Jurong Electrical Automation (JEA), Jurong Shipyard Pte Ltd. JEA is a department in JSPL which specialises in Electrical Construction for new ship building, ship repair and conversion projects. Our core functions include:
Cable installation
Cable termination
Electrical completion testing
Cable installation is identified as one of the most strenuous activity in our
department. First step in cable installation is to jack up the cable drum onto a cable
drum jack. Cable drums come in various sizes weighing from 500kg to 5000kg. The
conventional cable drum jack is less versatile because it is unable to suit various
sizes of drum and expose workers to various types of hazards. Therefore, we are
constantly spotting the workplace hazards and eliminate all these hazards through
innovation.
In line with our WSH policy, we have set our innovation project objective which is
to provide an accident free workplace for our workforce.
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b) Team’s Particular
Our team’s name is SPOT with the theme SPOT the hazards.
Team Composition:
Facilitator : Ohn Khin (Head of Department)
Team Leader : Alvin Beh Lip Teik (Engineer)
Members : Chew Teck Sin (Engineer)
Loh Heng Cheong (Engineer)
Teo Zhen Fa (Assistant Engineer)
Wong Wai Hoong (Executive)
c) Project Theme
In line with our project theme SPOT the hazards, we are constantly spotting the
hazards in our daily work activity and eliminate these hazards through innovation.
Through safety innovation, we have successfully achieved our objective to provide an
accident free workplace for our workforces.
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2. Summary of Project
a) Problem of Current Practices/Method:
Less Versatile
Figure 1: Conventional jacks are less versatile
Figure 1 shows the conventional jacks that we use to jack up a cable drum,
which is a screw jack and a fixed cable drum stand. The conventional jacks are less
versatile since it is unable to suit various sizes of cable drum. Due to various sizes of
cable drum we have, we have to use different sizes of cable drum jacks, which is
very costly.
Figure 2: Various sizes of conventional jacks
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Ergonomic Hazard
Due to the reason that the conventional jacks are less versatile, workers tend
to manually lift the cable drum stand as long as it is within their strength. Improper
posture of manual lifting may cause ergonomic problem such as back pain.
Figure 3: Improper posture of manual lifting may cause back pain
Pinch Point Hazard
When the workers manually lift the cable drum onto the jack, workers are
exposed to pinch point hazard between the steel pipe and the jack which may cause
hand and finger injury.
Figure 4: Pinch point hazard between the steel pipe and the jack
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Require Crane Lifting
If the cable drum is too heavy for manual lifting, we may need the aid of a
crane to lift up the cable drum onto the jack. This may expose the workers to
suspended load or swinging load hazard. If the workers get struck by the swinging
drum, the consequences might be quite serious.
Figure 5: Crane lifting
Require Fork-Lifting
Besides crane lifting, forklift is used to lift the cable drum onto the jack. If the
forklift operator lost control of the forklift, the workers may get struck by the moving
forklift and the consequences is very serious.
Figure 6: Fork-lifting
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Poor Mobility
Due to the poor structural design of the conventional jack, its mobility is quite
limited. Workers need to manually push and pull the jack to set up the jack in place;
this may expose the workers to physical hazards and may cause body injury.
Besides, excessive manpower is needed to operate the bulky and heavy jack.
Figure 7: Poor mobility
b) Causes
We used a fish bone diagram to do a cause-effect analysis and we had identified four
causes of all the above mentioned problems which are Man, Machine, Method and
Environment. The main cause was identified using the pareto principle which is the
Machine. Poor structural design of the tool is unable to suit various sizes of cable drum,
therefore the conventional jack require manual lifting, crane lifting or fork-lifting which
expose the workers to various type of hazards.
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c) Solution
Base on the problems we encountered, brain storming session was carried out by
our team members to come out with the best solution which is the innovative hydraulic
cable drum jack.
Figure 8: Hydraulic cable drum jack
The innovative tool hydraulic cable drum jack is designed to cater for all sizes of
cable drums. Hydraulic mechanism is selected because it is able to jack up a heavy load
by applying a minimum force.
Inner Frame
Bearing Support
Outer Frame
Hydraulic Jack
Base
Fixed Castor
Bearing Plate
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d) Abstract
The innovative hydraulic cable drum jack is so special because it:
Eliminates the needs of manual lifting, crane lifting and fork-lifting.
Prevents all the possible injuries such as hand and finger injury, back pain, struck by
falling/swinging drum and struck by forklift.
Suits various sizes of cable drum.
Ease of transportation to the desired workplace.
Improves productivity due to the reduction in operating time and manpower.
1. Project Write-Up
a) Project Selection and Definition
Reason for selecting project
1. Repeated hand and finger injuries cases due to the task of cable drum jack up.
2. Repeated back pain cases due to the task of cable drum jack up.
3. Workers’ feedback that the conventional jack has poor mobility.
4. Workers’ feedback that the conventional jack is less versatile.
Risk assessment conducted before improvement
Figure 9: Risk assessment matrix before improvement (medium region)
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From the risk assessment matrix of the conventional practise, the risk of
having back pain, hand/finger injury, struck by falling drum/moving forklift is in the
medium region (yellow), which should be further reduced to the low region (as
low as reasonably practicable).
Areas for improvement
To eliminate the necessity of manual lifting, crane lifting, fork lifting. Thus
preventing back pain, hand/finger injury and the possibility of being struck by
falling/swinging drum or moving forklift.
To increase the mobility of the structure by installing fixed castors to the
innovative design
To use another mechanism which makes the cable drum jack up operation less
strenuous, thus preventing ergonomic issues and improves productivity through
reduction in operating manpower and time
b) Analytical Techniques
Figure 10: Cause and effect analysis
We used a fish bone diagram to do a cause-effect analysis and we had
identified four causes of all the above mentioned problems which are Man, Machine,
Method and Environment.
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Figure 11: Pareto principle
The main cause was identified using the pareto principle which is the
Machine. According to the 80-20% principle, we have to tackle the 20% causes
which is the machine (conventional jacks) to solve the 80% effects which are the
back pain and injuries.
Figure 12: Hierarchy of control
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We used the hierarchy of control to come out with the best measures,
Elimination and Engineering Control to improve the conventional jack. By
eliminating the needs of manual lifting, crane lifting, we have successfully remove the
ergonomic, pinch point and suspended/swinging load hazards. Mobility and stability
of the tool have to be improved via engineering control measures.
c) Corrective Actions and Implementation
Alternate solutions
Figure 13: Alternate solutions
Other alternative solutions were considered such as gear jack, rack and
pinion and hydraulic jack.
Recommended solutions
We used a SIFE chart to vote for the best recommended solution in term of
Safety, Innovative, Feasibility and Efficiency. Hydraulic jack scored the highest (20)
among all other alternate solutions.
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Risk assessment conducted after improvement
Figure 14: Risk assessment after improvement (low region)
After the implementation of the innovative tool, we have conducted a risk
assessment and from the RA matrix, it is so obvious that we have successfully
eliminates the risk of being struck by falling/swinging drum or moving forklift and the
risk of having back pain, hand/finger injury has been reduced to low region (green).
Implementation
The innovative tool has been implemented in various projects such as West
Capricorn, West Leo, West Elara, Atwood Condor and ARC-II. The testing period
was 3 months and it is proven successful and has been continuously implemented
until today.
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d) Results Achieved
Tangible results
1. Eliminate hazards due to manual lifting, crane lifting and fork lifting.
2. Provide an accident free workplace.
3. Improve productivity.
4. Portable tool which can be transported to desired workplace with only a single
worker
Intangible results
1. Higher confidence in tool application.
2. Improve workers’ morale.
3. Owners’ satisfaction.
4. Better professional image.
e) Standardisation
Documentation
Figure 15: Documented into RA (JEA-EW-RA-002)
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For standardisation purpose, we have incorporated the use of the innovative
hydraulic cable drum jack into our RA and Safe Work Procedure.
Figure 16: Documented into safe work procedure (JEA-SWP-002)
Adoption and maintenance of new procedures
Figure 17: Maintenance checklist
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We have developed a maintenance checklist in order to ensure periodic
inspection and maintenance would be carried out on the tool.
f) Review and Sustenance
Review for future improvements
Review has been done on the hydraulic jack by collecting users’ feedback
and continuously innovates to improve the hydraulic jack. Innovation never stop here,
in the future, we would like to reduce the height and weight of the hydraulic jack.
Besides, its structural design would be improved so that it is able to be dismantled for
transporting.
Figure 18: Future improvement on structural design
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Team’s next project
Our team’s next innovation project would be the cable pulling automation. The
reason for this selection is because cable pulling is a strenuous task and it was voted
2nd highest in our priority list.
Figure 19: Next innovation project
g) Conclusion
In conclusion, our innovation project has successfully achieved the objectives to:
Eliminate all the hazards at work due to manual lifting, crane lifting and fork
lifting.
Prevent all the work injuries such as back pain, hand/finger injury, struck by
falling/swinging drum or forklift.
Thus achieving zero accident and provide a safe work environment for our
workforce.
We will continuously innovate for continual improvement.