Our Project Modification of Wind Sock Structure 3 Sep 2007

1. Good afternoon honorable judges, fellow teams, ladies and gentlemen. We are from Infineum Singapore Pte Ltd and we are here to present our project � �Modification of Wind Sock Structure�. Good afternoon honorable judges, fellow teams, ladies and gentlemen. We are from Infineum Singapore Pte Ltd and we are here to present our project � �Modification of Wind Sock Structure�.

2. Our Project � Modification of Wind Sock Structure3 Sep 2007

3. Our team is known as �Maintenance Team�. As you can see, we have our HSE manager as the Facilitator, Leader being Mr Raj and the rest as members; Mr Foo, Mr Jagan, Mr Kalai and myself. I am the first speaker for today, covering introduction, followed by Mr Jagan covering initial phase of the project. Then we will have Mr Raj to talk on the project selection and lastly to end of the presentation we have Mr Kalai. (Point to the presenters � presenters to wave) Our team is known as �Maintenance Team�. As you can see, we have our HSE manager as the Facilitator, Leader being Mr Raj and the rest as members; Mr Foo, Mr Jagan, Mr Kalai and myself. I am the first speaker for today, covering introduction, followed by Mr Jagan covering initial phase of the project. Then we will have Mr Raj to talk on the project selection and lastly to end of the presentation we have Mr Kalai. (Point to the presenters � presenters to wave)

4. Our team mates met every month from the start of the project to all the way from Oct 06 to the completion of project, Feb 07. However, in Jan this year, one of our members was not able to attend the meeting due to other urgent commitments.Our team mates met every month from the start of the project to all the way from Oct 06 to the completion of project, Feb 07. However, in Jan this year, one of our members was not able to attend the meeting due to other urgent commitments.

5. Just like any other projects, we had a schedule to follow and it was followed faithfully. Frankly, there were very few changes but it did not affect the project. The schedule was based on Plan, Do, Check, Action, which is in short known as PDCA cycle.Just like any other projects, we had a schedule to follow and it was followed faithfully. Frankly, there were very few changes but it did not affect the project. The schedule was based on Plan, Do, Check, Action, which is in short known as PDCA cycle.

6. Project Selection �Brainstorming Session Total 13 suggestions were contributed; only three were qualified to be safety & health related project. Three suggestions or safety concerns were as follows: Problems/ Risks Involved When Changing of Wind Sock. Problems/ Risks Involved Using Emergency Chlorine Shut-Off Valve. Risks Involved Without Proper Access platform for operating valves There were a total of 13 suggestions but only 3 were qualified to be safety and health related projects� which are as follows �.. (read from the screen). There were a total of 13 suggestions but only 3 were qualified to be safety and health related projects� which are as follows �.. (read from the screen).

7. Project Selection Matrix � Risk Assessment For selection of project, a selection matrix was developed. Since these projects were pertaining to safety and health, we used the highest number of hazards and risk level as the selection factors for decision making. Risk assessments for all of them were conducted and from there the total number of hazards and risk level was determined. �Problems or Risks Involved When Changing of Wind Sock� being the highest number of hazards; that is 10 and contributing to a �Medium Risk�, was selected as a project. For selection of project, a selection matrix was developed. Since these projects were pertaining to safety and health, we used the highest number of hazards and risk level as the selection factors for decision making. Risk assessments for all of them were conducted and from there the total number of hazards and risk level was determined. �Problems or Risks Involved When Changing of Wind Sock� being the highest number of hazards; that is 10 and contributing to a �Medium Risk�, was selected as a project.

8. Risk Assessment � Before Implementation After afternoon everyone. I�m Jagan. Pls allow me to begin my part with the risk assessment conducted before implementation phase. The team sat together with our HSE representatives to conduct the risk assessment. Altogether 10 hazards were identified. Of which three were Medium Risk and the rest were Low risk. The three medium risks were Manual handling, crane topple and labourer not understanding the hazard. In a snapshot, you can see most of the hazards were contributed by usage of cranes.After afternoon everyone. I�m Jagan. Pls allow me to begin my part with the risk assessment conducted before implementation phase. The team sat together with our HSE representatives to conduct the risk assessment. Altogether 10 hazards were identified. Of which three were Medium Risk and the rest were Low risk. The three medium risks were Manual handling, crane topple and labourer not understanding the hazard. In a snapshot, you can see most of the hazards were contributed by usage of cranes.

9. Implementation Steps of Operation BEFORE Implementing Selected Solution. To understand better on the operation of wind sock and the details of it, we have a flowchart here on the screen. In all there were 6 steps; from step 1, which is the preparation and planning phase. Plan for manpower, accessories and crane services. ....... The rest read from slides To understand better on the operation of wind sock and the details of it, we have a flowchart here on the screen. In all there were 6 steps; from step 1, which is the preparation and planning phase. Plan for manpower, accessories and crane services. ....... The rest read from slides

10. Location of Windsocks � Before Implementation This was where for some of the windsocks were located, on the pipe racks, slanted roof top and tank tops. There were actually no proper platforms for changing of wind-socks This was where for some of the windsocks were located, on the pipe racks, slanted roof top and tank tops. There were actually no proper platforms for changing of wind-socks

11. Illustration ofChanging Wind Sock-Before Implementation We now going to show you an illustration of how we used to change wind socks. This is before implementation. We needed minimum 5 men to operate. One crane driver, rigger, signaller, two in the man-cage of course and of course not forgetting lifting supervisor to be stationed there till operation is over.We now going to show you an illustration of how we used to change wind socks. This is before implementation. We needed minimum 5 men to operate. One crane driver, rigger, signaller, two in the man-cage of course and of course not forgetting lifting supervisor to be stationed there till operation is over.

12. Analytical Techniques �Root Cause Analysis For further understanding of the problems, a fish-bone chart was developed. To give some examples of the causes, we have failure of lifting equipment or machine and potential crane topple under �Machine� category. Under �Man� category, excessive manual handling and fall from height. We also have too many procedures to be adhered to and long duration-fatigue under �Method�. Under �Materials� category, we have wind socks coming in different sizes causing mis-matched. Lastly, under � Environment�, we have housekeeping issues and exhaust and spill issues.For further understanding of the problems, a fish-bone chart was developed. To give some examples of the causes, we have failure of lifting equipment or machine and potential crane topple under �Machine� category. Under �Man� category, excessive manual handling and fall from height. We also have too many procedures to be adhered to and long duration-fatigue under �Method�. Under �Materials� category, we have wind socks coming in different sizes causing mis-matched. Lastly, under � Environment�, we have housekeeping issues and exhaust and spill issues.

13. From the causal analysis, we have sum up the causes into 5 categories. Safety being the most priority, we also have Human, cost , time and method. We used the chart on the screen for further analysis. Longer duration and method were not considered to be key factors since safety cannot be compromised even if it takes longer period or meticulous methods. Max of 4 is given to these two factor. The rest were given Max of 5. We wanted to achieve 75% reduction in all of these factors. From the causal analysis, we have sum up the causes into 5 categories. Safety being the most priority, we also have Human, cost , time and method. We used the chart on the screen for further analysis. Longer duration and method were not considered to be key factors since safety cannot be compromised even if it takes longer period or meticulous methods. Max of 4 is given to these two factor. The rest were given Max of 5. We wanted to achieve 75% reduction in all of these factors.

14. Proposed Solutions Proposal 1 - Telescopic Structure: Simple and effective idea Not practical; Corrodes easily and flimsy. Expose to inclement weather; possibility of the wind sock structure to topple. Expose to caught in between hazard while adjusting the telescopic pole Proposal 2 - Pulley System: Not effective. Design not suitable for strong wind condition. Rope can get entangled with wind sock and pulley. Pulley requires maintenance Proposal 3 - Two-Section Structure Safe, effective and strong Easy to implement. Minimum maintenance was required. To resolve the problem, we came up with three proposals. The first proposal was �Telescopic Structure� which is believed to be simple and effective but not very practical as it corrodes easily and can be flimsy. When exposed to inclement weather there is a possibility of the wind sock structure to topple. It can even create caught in between hazard while adjusting the telescopic pole. ��read the slides.To resolve the problem, we came up with three proposals. The first proposal was �Telescopic Structure� which is believed to be simple and effective but not very practical as it corrodes easily and can be flimsy. When exposed to inclement weather there is a possibility of the wind sock structure to topple. It can even create caught in between hazard while adjusting the telescopic pole. ��read the slides.

15. Proposed Solutions �Selection We had the luxury to have three proposals. But we need to choose one. So we came up with a selection matrix with a few selection factors. That is Safety and Health, Installation Cost, Cost Saving, Effectiveness and Efficiency and lastly Within the Team�s capability. Each factors is given the rating from 0 to 10, 0 being the lowest and 10 being the highest. So the proposed solution with the highest score will be the chosen one. As you can see, the �Two-Section Structure� was awarded the highest.We had the luxury to have three proposals. But we need to choose one. So we came up with a selection matrix with a few selection factors. That is Safety and Health, Installation Cost, Cost Saving, Effectiveness and Efficiency and lastly Within the Team�s capability. Each factors is given the rating from 0 to 10, 0 being the lowest and 10 being the highest. So the proposed solution with the highest score will be the chosen one. As you can see, the �Two-Section Structure� was awarded the highest.

16. Selection Criteria Rating Safety and Health - 1 is high (high risk) and 10 is low (0 hazard) Installation Cost - 1 is high cost (>S$ 20, 000) and 10 is low cost (<S$ 1000) Cost savings - 1 is less savings (<S$ 1000) and 10 is high savings (>S$ 20, 000) Effectiveness and Efficiency - 1 is low (Less effective and efficient) and 10 is high (Very Less effective and efficient) Within Team Capability - 1 is low (take more than> 12 months to implement proposal & and 10 is high (take less than 3 months to implement proposal ) Here is the criteria selection rating�.. Show for 5 secHere is the criteria selection rating�.. Show for 5 sec

17. Finalizing Selection Selection of Proposal. Based on the ranking score and comparison made in the evaluation of proposed solutions, the team selected the �Two Section Structure� solution. Management Presentation. Short presentation of the study was tabled for the management�s endorsement. Team was commended for its efforts and the proposed solution was endorsed for implementation. The Two-Section Structure proposed solution was selected and a short presentation was tabled for endorsement at our management level meeting. The team was commended for its efforts and the proposed solution was endorsed for implementation. The Two-Section Structure proposed solution was selected and a short presentation was tabled for endorsement at our management level meeting. The team was commended for its efforts and the proposed solution was endorsed for implementation.

18. Risk Assessment � After Implementation Upon implementation, risk assessment was conducted to determine the number of hazards and risk level. From originally 10 hazards it has now been reduced to only 5 hazards. We also had hazards with medium risks to reduce to either low-risk or being eliminated. No usage of equipment/tools to fix wind socks. The hazards shown here are low risk. Minimal manual handling and minimal housekeeping issues. As a practice, however small job it can be we still emphasize on last minute risk assessment. Overall, it has become from a medium risk to a low risk activity. Upon implementation, risk assessment was conducted to determine the number of hazards and risk level. From originally 10 hazards it has now been reduced to only 5 hazards. We also had hazards with medium risks to reduce to either low-risk or being eliminated. No usage of equipment/tools to fix wind socks. The hazards shown here are low risk. Minimal manual handling and minimal housekeeping issues. As a practice, however small job it can be we still emphasize on last minute risk assessment. Overall, it has become from a medium risk to a low risk activity.

19. Implementation Steps of Operation AFTER Implementing Selected Solution. The steps for operation have been reduced from 6 steps to only 3 steps. With reduced steps, admin work and coordination work have also been reduced, which leads to reduction in time which means less exposure to hazards The steps for operation have been reduced from 6 steps to only 3 steps. With reduced steps, admin work and coordination work have also been reduced, which leads to reduction in time which means less exposure to hazards

20. Re-Location of Windsocks �After Implementation For better accessibility and to create a proper or stable platform, the windsocks have been re-located to either roof-tops or tank-tops. For better accessibility and to create a proper or stable platform, the windsocks have been re-located to either roof-tops or tank-tops.

21. Illustration of ChangingWind Sock-After Implementation We would like to now show you an illustration of how we change wind sock now as compared to before.We would like to now show you an illustration of how we change wind sock now as compared to before.

22. Illustration of ChangingWind Sock- After Implementation Here is a pictorial view of how we change the wind socks after implementation. Go through the pics. Here is a pictorial view of how we change the wind socks after implementation. Go through the pics.

23. Total Cost forImplementation & Installation Each location: S$600/-Structure� solution. Five Locations: One-time Cost of S$3,000/- only

24. Results Achieved �Tangible Results Cost Savings

25. Results Achieved �Tangible Results Save Time

26. Results Achieved �Intangible Results

27. Variation of ResultsBetween Results & Initial Target: Firstly under safety, from 10 hazards we have reduced to 5 hazards and moreover medium risks activities have also been reduced to low risks. There is an estimated hazard reduction by 75%. For Human, we have reduced from 5 men to only one man; OMO operation. Cost of operation we have reduced by 86%. Man exposure has also been reduced by 83% and lastly, the method has been reduced by half; 6 steps to only 3 steps. Firstly under safety, from 10 hazards we have reduced to 5 hazards and moreover medium risks activities have also been reduced to low risks. There is an estimated hazard reduction by 75%. For Human, we have reduced from 5 men to only one man; OMO operation. Cost of operation we have reduced by 86%. Man exposure has also been reduced by 83% and lastly, the method has been reduced by half; 6 steps to only 3 steps.

28. Risk Reduction In Summary

29. Standardization

30. Review & Sustenance

31. Review & Sustenance

32. Conclusion

36. The Maintenance TeamThanks you

37. Question Time