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Jurong Electrical Automation Jurong Shipyard Pte. Ltd.

29, Tanjong Kling Road Singapore 628054

1. INTRODUCTION a) Teams 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.

b) Teams Particular Our teams 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.

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 3

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

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

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.

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.

Inner Frame Bearing Support Outer Frame Bearing Plate

Hydraulic Jack Base Fixed Castor

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.

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) 8

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.

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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Teams next project

Our teams 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.

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