WSH Innovation Awards 2008 - Manufacturing

1. WSH Innovation Awards 2008 - Manufacturing Presented by : Lim Siak Pin

2. Working At Height Solution For Gun Cupola AOS 40mm/L70 Naval Air Defence Mount (NADM) 330 Automatic Gun

3. 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 Team Name And Particulars OLOGBO 3

4. Background • Allied Ordnance of Singapore (Pte) Ltdfocuses on 2 core business areas: • Servicing of gunnery and torpedo launcher weapon systems • Export sales of the NADM and FADM guns • Scope of workfor AOS 40mm / L70 NADM 330 production includes: • Assembly • Testing • Quality Control • Firing Acceptance • High risk factorsassociated with working at height was identified - This could lead toserious injuriesor possibly,permanent disabilities. 4

5. 3.7 m 0.7 m Height from ground to top of Gun Cupola 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 Ministry of Manpower (MOM) Workplace Safety and Health Act (WSHA), Act 7 of 2006 5

6. 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

7. Analytical Techniques • Severity Rating vs. Likelihood Rating Risk level score > 4 shall be regarded as significant risks, and shall be given priority in the risk control planning.

8. Analytical Techniques • Severity Rating • Likelihood Rating

9. Analytical Techniques • Risk Levels

10. Analytical Techniques • HIRADC Results

11. Securing of Safety Line Cost Full Harness Crane Safety Belt Fixture Cupola Ladder Fixture Working on Top of Gun Cupola Scaffolding Falls & injuries - no safety line Ladder Falls & injuries - with Safety Belt Forklift Falls & injuries - with Full Harness Boom Lift Men Method to reach Top of Gun Cupola Analytical Techniques • Cause & Effect Analysis (MUDA identified)

12. Analytical Techniques • Comparison Table

13. Securing safety harness to ladder 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

14. Fixture Design 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.

15. 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

16. 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

17. 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

18. 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

19. Results Achieved • HIRADC after implementation

20. 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.

21. We believe in Safety 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.

22. Thank You 22