Innovation Project

Presented by:Wang Hao

Contents

• Project Objective• Introduction• Survey• Problem Identification/Analysis• Design Objective• Generation of Solutions• Final Idea• Fabrication• Tangible/Intangible Benefits• Conclusion• Future Improvement

Project Objective

• Analyze the current methods, the potential risks and inefficiency of conventional practice.

• Create an innovative, highly efficient, user-friendly device to reduce such problems.

• Increase the safety and productivity.• Reduce material wastage.

Project SelectionProblem Identifications Consequences

IIneffective ventilation system for confined space

• Flawed welding

IIUnprotected holes in deck plates during renewal

• Potential falling hazard• Potential fire and explosion hazard

III Random marking of steel plates

• Potential mis-communication• Potential safety hazard

IVInefficient method of pipe railing deployment

• Potential Falling Hazard• Time Loss• Material Wastage

Decision Matrix

Criteria Description

Urgency Whether requires immediate improvement

Capability Ability of the person

Feasibility Whether the problem can be resolved with a workable solution

Benefit The amount of benefit brought to the yard

Decision Matrix

TopicCriteria Total

(20 max)Severity

(5 max)

Capability

(5 max)

Benefits

(5 max)I 4 2 3 9II 2 4 2 8III 2 5 3 10V 4 5 4 13

Introduction

• Deck plate renewal is a ubiquitous job for Hull Department.

• Railings have to be deployed to prevent personnel/objects from falling.

• The pipes need to be secured to assure the structural integrity.

Current Practice

• Welding (standard)• Miscellaneous improvisation• Used pipes are mostly discarded• No toe board, below 1.1m

Welding (standard)

Welding (standard)

Welding (standard)

• No toe board – safety hazard• Time-consuming• Can be fairly messy, which looks

unprofessional.• Material wastage

Miscellaneous Improvisation

Safety Hazard

• When people do this

Survey

• Are pipe railings used often?• Does welding the railings troublesome and

takes time?• Is the welding quality good?• Do you feel safe around the railings?• What do you do to the pipes after using them

as railings?

Problem Identification

• Wastage of material• Time loss• Safety hazard

Problem AnalysisLack of awareness of the wastage of the material

Unable to detach welded pipes without damaging them

Intrinsic properties of steel

“It’s okay” attitude

Wastage of Material

Problem AnalysisLack of training/experience

Intrinsic property of welding – it takes time

Intrinsic properties of steel

Attitude issues

Time Loss

Problem Analysis

Fail to weld properly

Intrinsic stiffness and yield point of steel

Attitude Issues

Safety Hazard

Fail to comprehend the importance of toe board and 3-tier regulations

Design Objective

• No need to weld & instant deploy – save time• Reduce potential safety hazard• Reduce material wastage• No defected look – professionalism.

Design Objective(Pareto Chart Comparison)

Safety Time Material0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

BeforeAfter

Generation of Solutions

• Reusable + fast deployment = collapsible

• 1. How to collapse?• 2. How to secure?

How to collapse?

• Idea 1• Zip & Zap

How to collapse?

• Idea 2• Telescopic

How to Collapse?

• Final idea

How to secure?

• Idea 1

How to Secure?

• Idea 2

How to Secure?

• Idea 3

How to Secure?

• Idea 4

How to Secure?

• Final idea

Final idea

Final idea

Final idea

Final idea

Final idea

Tangible Benefit

• Reduce the material wastage caused by disposing of railings

• Increased productivity by reducing fabrication time

Intangible Benefit

• Increased safety comforts workers and thus brings up productivity

• High durability which result in lower maintenance

• Enhanced professional image of workforce• Instill pride in workmen and increase morale

and productivity

Conclusion

This innovative design of collapsible railing will bring several positive changes to the shipyard:• Increased productivity• Lower cost of production• Increased safety• Environmental-friendliness• Professionalism