Establishment Of Accident Free

Production Area

Welcomes You To

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Than sorry.Better safe,

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Ashish Rakshit

Debdeep

Bhattacharjee

Swapan Mondal

Sushmita Dutt

Emamun Ali Sha

Aritro Das

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STEP 1:

Identification Of Problem

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A

• Failure of injection moulding nozzle

• Accidents during maintenance of Grinding machine

B• Leakage of Hydraulic oil

• Live circuit in contact with equipment body

C

• Equipment damage due to voltage fluctuations

• Suspended particulate matter and flyaway

• Accidents during machine maintenance

• Injuries during mould transport and storage

• Accidents during hopper loading

• Burns due to handling of hot products

A- Can be solved by themselves

B- Can be solved with help of other departments

C- Requires management support

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STEP 2:

Selection Of Problem

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Problems Pre determined criteria weightage rank

fatigue quality safety environment production

Equipment damage due to voltage fluctuations 1 1 1 3 1

Live circuit in contact with equipment body 1 1 1 3 1

Suspended particulate matter and flyaway 1 1 1 3 1

Accidents during mould maintenance 1 1 1 3 1

Accidents during EOT crane maintenance 1 1 2 2

Failure of injection moulding nozzle 1 1 1 3 1

Injuries during mould transport and storage 1 1 2 2

Slippage of mould due to improper maintenance of

Platens1 1 1 1 3

Leakage of Hydraulic oil 1 1 1 3 1

Accidents during hopper loading 1 3

Accidents during maintenance of Grinding machine 1 1 1 3

Burns due to handling of hot products 1 1 3

Absence of appropriate lighting conditions 1 1 2 2

Fire hazards 1 1 1 3 1

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0 1 2 3 4 5 6 7 8

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Number of accidents

Pro

ble

m n

um

ber

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Sl. No Problems Frequency Percentage

1Injuries during mould

handling8 34.78

2Accidents during

machine maintenance 5 21.74

3Suspended particulate

matter and flyaway4 17.39

4Equipment damage due

to voltage fluctuations4 17.39

5Live circuit in contact

with equipment body1 4.35

6 Leakage of Hydraulic oil 1 4.35

7 Fire hazards 0 0

TOTAL 23 100

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0

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60

70

80

90

100

0

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Injuries duringmould transport

and storage

Accidents duringmould

maintainence

Suspendedparticulatematter and

flyaway

Equipmentdamage due to

voltagefluctuations

Live circuit incontact with

equipment body

Leakage ofHydrolic oil

Fire hazards

Frequency Cum Freq

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STEP 3:

Defining The Problems

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Problem 1

• Injuries during mould handling– EOT break failure, Loose parts falling off during transport of mould by EOT crane, mould falling on an operator’s feet

Mould mounted on

machine

Mould carried from

workshop to machine

Mould taken to Workshop

Mould carried by EOT crane

Mould Dismounted

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Production is carried

out

Maintenanceis carried

out

Controlpanel is

opened up

Machine is turned off

Cutting machine is restarted

Machine cover is

opened and blades are cleaned

Cutout plastics are

emptied

Main power switched off

Cuttingmachine is

switched off

Problem 2

• Accidents during machine maintenance–control panel maintenance of injection machine, grindingmachine maintenance.

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The plastic granules

are stored

The plastic is converted to

smaller granules

Scrap plastic is inserted into the machine

Grinding machine is

started

Problem 3

• Suspended particulate matter and flyaway – while operating the grinding machine

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Production is carried

out

Machine is operated

Electricalsupply is switched

on

Problem 4

• Equipment damage due to voltage fluctuations – Spikes in voltage may damage the machine

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S.no Activity Responsibility Oct’

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Nov’1

6

Dec’1

7

1 Defining the problem All members

2 Analysis of problem All members

3 Identification of

causes

All members

4 Finding out root

causes

All members

5 Data analysis Ashish Rakshit

6 Developing solution All members

7 Foreseeing resistance All members

8 Trial Implementation Swapan Mondal

9 Regular

implementation

All members

10 Follow up and review All members

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STEP 4:

Analyze The Problem

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What is the problem?

Injuries during mould handling

Where is the problem?

Production area

When is the problem observed?

During transportation of mould

Who noticed the problem?

The operators at production line

How did the problem occur?

1) EOT brake failure

2) Falling of loose parts during mould handling

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What is the problem?

Accidents during machine maintenance

Where is the problem?

Production zone (machines)

When is the problem observed?

During machine maintenance

Who noticed the problem?

Maintenance department operators

How did the problem occur?

1)Sparks during machine control panel maintenance

2) Accidentally turning the power supply on during

maintenance

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What is the problem?

Suspended Particulate Matter and Flyaway

Where is the problem?

Production zone

When is the problem observed?

During machine operation

Who noticed the problem?

Operators at production zone

How did the problem occur?

1) Absence of protective eyewear

What is the problem?

Equipment damage due to voltage fluctuations

Where is the problem?

Production area

When is the problem observed?

During production

Who noticed the problem?

Operators at production zone

How did the problem occur?

1) Voltage fluctuations in power supply

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STEP 5:

Identification Of Causes

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Injuries during

Mould Handling

Protective

gear not used

Loose parts falling

off from moulds

EOT crane

break failure

Protective gear

not provided

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Injuries during

Machine

Maintenance

Protective

gear not used

LOTO not

implemented

Human error during

machine maintenance

Protective gear

not provided

Failure of

Limit Switch

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Suspended

Particulate Matters

and Flyaway

Protective gear

not provided

Protective

gear not used

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Equipment Damage

due to voltage

fluctuations

Voltage stabilizer

not provided

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STEP 6:

Finding Out Root Causes

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EOT crane failure

Irregular maintenance

Loose parts falling from

mould

Checks on mould not performed

before transport

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Power supply switched on accidentally

Lack of attention of

Operators/Human error

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Injuries due to Suspended particulate

matter

Protective eye gear and

gloves not used

Absence of safety

measures

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Fluctuations in power supply

Absence of Power stabilizer

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STEP 7:

Data Analysis

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0

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60

70

80

90

100

0

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Injuries duringmould transport

and storage

Accidents duringmould

maintainence

Suspendedparticulatematter and

flyaway

Equipmentdamage due to

voltagefluctuations

Live circuit incontact with

equipment body

Leakage ofHydrolic oil

Fire hazards

Frequency Cum Freq

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• Brain storming

• Data Collection

• PDCA

STEP 8:

Developing Solutions

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Provide workers with Safetyhelmets,

Industrial boots and safety

harness

Making sure that the mould

to be transported has no loose parts

Routine EOT Crane

maintenance

Problem 1

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Implementation of LOTO

Providing Rubber matsand gloves to

prevent electrical

shocks

Providing safety eye gear during

machine maintenance

Problem 2

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Provide workers

with protective eye gear

Take the cutting

machine outdoors

Problem 3

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Using a servo for stabilizing

power supply

Problem 4

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STEP 9:

Foreseeing Problems Of

Resistance

Fund allocation from management

Periodic training and safety drill implementation

Providing SOP's for machine operation

Enforcing strict safety measures and providing incentives

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STEP 10:

Trial Implementation

And Check

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Regular checks are conducted to ensure compliance with safety

regulations.

Periodic drills conducted and attendance of employees is

monitored.

Routine maintenance checks for machinery and components.

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• To provide a zero accident work

environment

• To eliminate all potential risks associated

• To provide enhanced job satisfaction and

sense of security to employees

• To involve all employees in constant

improvement and implementation of

safety regulations

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STEP 11:

Regular Implementation

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Problem 1 Problem 2 Problem 3 Problem 4

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• Minimized Property Damage

• Reduction of machine downtime

• Increased financial savings

• Efficient use of available man-power

• Increased employee morale

• Safer working environment

• Job satisfaction for employees

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STEP 12:

Follow Up And Review

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Step No. Activity Responsibilities Oct'16 Nov'16 Dec'16

3 Defining the Problem All MembersTarget

Achieved

4 Analysis of the problem All MembersTarget

Achieved

5 Identifying the causes All MembersTarget

Achieved

6 Finding out the root causes All MembersTarget

Achieved

7 Data Analysis A.Rakshit & S.MondalTarget

Achieved

8 Developing Solution All MembersTarget

Achieved

9 Foreseeing Resistance All MembersTarget

Achieved

10 Trial Implementation S.Mondal & C.DasTarget

Achieved

11 Regular Implementation All MembersTarget

Achieved

12 Follow up/Review S.Mondal & C.DasTarget

Achieved

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But,

We do have

one more

thing!f

f

f

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Increased water tank capacity

Automatic sprinklersystem

Fire extinguishers

Assembly point

marking

Temperaturesensors

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For the next project

we will be working

on:

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