ST Marine - Improvement Process For Vessel Windows Installation

13th CONVENTION FOR WORKPLACE SAFETY AND

HEALTH INNOVATIONS IN MARINE INDUSTRY

IMPROVEMENT PROCESS FOR VESSEL WINDOWS

1

INSTALLATION

TEAM: ICE ST MARINE

IntroductionTeam Background

Initiative

We take initiative in identifying potential hazards, injuries and property

losses in the area of occupational safety and health.

Your Trusted Partner2

losses in the area of occupational safety and health.

Creative

We are creative in solving problems.

Effective

Forging ahead with innovative solutions, which are effective in creating a

safe work environment in fabrication workshops.

Introduction

Team Member

Leader Member Safety


Our team, “ICE” was formed in July 2008 to focus on safety issues within the Hull fabrication process.

Li Da Hua

Snr Engineer (Process)

Logan Dhananjeyan

Chargehand (Hull)

Kyaw Thu Ya

Snr Safety Officer

Project Objective

• The main objectives of this project are to reduce the cycle

time and man-hour of window penetration installation

process and to eliminate all potential safety hazards.


• Review the methodology of window installation on board

• Invent and fabricate a window installation fixture to meet the

same intent but at a more EFFECTIVE and most SAFE

manner.

Project Theme


manner.

Project Selection & Definition

Acting

Force Stopper

Window

Two type of Window Installation


Force Stopper

SupportZ

Y

X

Penetration installation


Where is the window installation?


Window install on the side shell

Current Window Installation Method


• Positioning and tack welding of

Stopper

1


• Positioning and tack welding of

stopper outside the opening.

• Transfer window in upright

position to installation site

• Positioning of support inside the

opening by means of tack welding.

2

3



4 5


• Rigging of the window and placing it

upon the support

• Adjust window position and insert

window frame into the opening



6 7 8


• Hammer the window frames into the opening with cushion from wooden

plank and ensure that the window frames are fully in contact with the

stoppers.

• Tack weld the window frames onto the side shell

• Remove stopper and support brackets

• Grind away the welding scar

No. Activity Hazard Hazard Effect S L Risk Level

1 Transfer of materials and tools Falling object Minor injury 3 1 4L

2 Positioning the stopper and supporter Falling object Major injury 3 3 6M

Burning by welding spark Major injury 3 2 5M

Contact with hot surface Major injury 3 1 4L

3 Transfer the window to installation location Injure by window fall Major injury 3 4 7H

Widow fall down and damage Major injury 3 4 7H

Hitting foot Minor injury 2 2 4L

4 Lift up the window and rest it on the supports Widow fall down and damage Major injury 3 4 7H

AnalysisRisk Assessment Before Improvement

Your Trusted Partner

4 Lift up the window and rest it on the supports Widow fall down and damage Major injury 3 4 7H

Finger pinch Major Injury 3 3 6M

5 Adjusting the window and slot into opening Finger pinch Major Injury 3 3 6M

Strike by wooden stick Minor injury 3 4 7H


6 Tack weld window frame Expose to radiation Minor injury 2 2 4L

7 Remove stopper and supporter Struck by flying particle Minor injury 2 1 3L

Strike by hammer Minor injury 3 4 7H

Falling object Major injury 3 3 6M


8 Pickup grinding Hand cut by grinding disc Major injury 4 3 7H

Strike by flying particle Minor injury 2 1 3L

AnalysisRoot Cause Verifying

Injuries and

ManMaterial

Temporary support

Opening wrong size

Different sharp of window

Worker fatigue

Skill requirement

Workers’ carelessInexperience

Window heavy

Numbers of tools

Lack of instructions

Long fitting time

No pre-check

Lack of safety

awareness

No holding

window properly

Different thickness of side shell

Window is brittle

Your Trusted Partner 12

Injuries and property damage incurred during window installation on board

Method Tools

Grinding disc fly out

Cut during grinding

Tools fall from height

Window is heavySkill requirement

for fitting

Too many tack

welding

Manual handling

window transferring

Grind welding scar

Long fitting time

Tack weld support

and stopper brackets

No proper equipment

Manual handling

window adjustment

Non clear Operation

procedure

No proper fixture

Lack of instruction

Support removalWear and tear

Poor maintenance

and no pre-check

Lack of instruction

InexperienceCareless

Numbers of tools

Strike by hammer

Burn by welding spark

Operation not

ergonomic


Root Causes

Risk Root Causes

� High risk of work related injury

� Hand/ finger/back - manual handling

� Eye - grinding and tack welding

operation

� Too many tools use for window

installation.

� No proper fixture use for manual

handling of heavy window.


operation

� Body – work at high

� High risk of catching fire

� Sparks from heavy grinding

� Cutting and tack welding operation

� Window damage- transferring

handling of heavy window.

� Too much tack welding and pickup

grinding.

� No proper tools for window fitting and

support removal.

� Too many temporary support used.


Areas for Improvement

� Positioning and tack welding of stopper and support brackets.

� Transfer window to installation in upright position

� Rigging of window and placing it onto temporary support


� Adjusting window frame position

� Hammering of window frame in position.

� Remove stopper and support brackets

� Pick up grinding

Analysis

Risk Control

Elimination

Substitution


Engineering Control

Administration Control

PPE

Eliminate pick

up grinding

Reduce object

falling

possibility

Reduce the

number of

Eliminate finger

injuries

Eliminate strike

by hammer

Eliminate cut by

grinding disc

Reduce Window Installation Risk

Analysis

Solutions


up grinding

Eliminate tack

welding

Fixture jig to replace

the stopper and

temporary support

plate

number of

objects (tools)

Fixture jig can

provide same

function as all the

tools

by hammer

Use different

alignment

method

New Fixture

Innovation & Implementation

Alternative Solution 1


• Only can provide z-axis alignment. (up & down)

• Not accurate enough for alignment

• Installation at height is very difficult due to its heavy weight.

• Reduce tack welding and grinding job, but still need to install temporary

lifting eye lug.

Z

Y

X

Alternative Solution 2



• Window clamping method is minimum, only suitable for particular size of circular

window installation.

• y-axis adjustment not accurate enough. (left & right)

• Not able to adjust in z –axis. (Up and down)

Z

Y

X

� Jig is able to apply force in 3 directions (x, y ,z axis), easily adjustment in 3 dimensions

� Jig is able to adapt to all type and size of window installation


Innovation Idea


� No need to install the stopper and support on-site

� Able to proceed welding after fitting immediately

� Easy to transfer window

� Portable

� Easy design and user friendly

Jig Design

Window Installation Jig

Clamping Function

Design Concept


Transfer Function

Adjustment Function

Jig Design

Design Concept


Jig Design

Clamping System Design


• Able to clamp various different shape of window

• Able to clamp different size of window

• Provide a upright clamping position

Jig Design



• When jack piston extends, a force is applied on the stationary

frame, which is fixed onto the main frame. As a result, the top

adjustable clamp moves downward, thus providing a downward

force on the object.

• This clamping force prevents the window frame from tilting.

Jig Design


Jack released at low


Jack released at low

position

• The purpose of the springs is to prevent the jack from falling before clamping

commence.

• To allow fast restoration of the top adjustable frame after the jacking force is released.

Jack extend at high position

Jig Design



• The height of stationary frame is able to be adjust to height of the installing

window by various locations.

• Adjustable position of the top clamp point.

Jig Design


The clamp point

surface with texture

to maximize contact


•The bottom two clamp points are able to rotate in all required angle so that it

can accommodate different outer profiles of window.

•The position of bottom clamp point is able to be adjust depend on the width of

the window (X-axis)

Jig Design



Circle Window Clamping points

Rectangular Window Clamping points

Jig Design

Adjusting System Design


Jig Design

Adjusting System Design


• Assembly of two adjusting tables, to provide adjusting movement in x and y axis

Jig Design

Transfer System Design

Release

Break


It is a 1.5 ton scissor table with 4 lockable wheels

Maximum lifting high is 1.2m

WheelsPedal

Jig Design



Counter weight will increase the balance and

prevent jig fall down during window

transferring

Jig Design



• Four lifting eye lugs are installed at four

corners of the jig.

• The clamping system is collapsible

during transportation, the CG will be lower

down in order to reduce the risk of lifting

hazard.

Process after Improvement

1 2


Clamp the window on the fixture Transfer window to installation location

Allow the fixture is parallel to the side

shell

Lock 4 wheels

3 4


5 6


Jack up to the installation level z-axis Adjustment in x and y axis

Window slot in to the opening

7


8 9


Tack weld the window frame on the side

shell

Release the jack and remove the fixture

Results Achievement

No Activities Hazards Hazard effect S L Risk Level

1 Clamp the window on jig Injury by window fall down Major injury 3 1 4L

Window fall down and damage Major injury 3 1 4L

2 Transfer window to installation location Jig trap and fall down Major injury 3 1 3L

3Installation setup. ( fixture parallel to side

shell, lock wheels)

Unsafe practiceMinor injury 2 2 4L

4 Adjustment in x, y and z axis Unsafe practice Minor injury 1 1 2L

Risk Assessment after Improvement


4 Adjustment in x, y and z axis Unsafe practice Minor injury 1 1 2L

5 Slot in the window Window frame surface scratch Minor 1 1 2L

6 Tack weld the window frame on the side shell Expose to radiation Minor injury 2 2 4L

7 Release jack and remove jig Finger pinch Minor injury 3 1 4L

Results Achievement

Risk Level Comparison


Results Achievement

Before Improvement After Improvement

1. The average risk level of window

installation on board is medium to

high level

1. The average risk level of window

installation on board is improved to low level

2. 5 reported accidents from year 06 - 09 2. No reported accident till now after

implementation

Tangible Benefits


implementation

3. Hull fitting window installation are

carried out 4 or more employees

3. Window installation can be carried out by

one employee

4. Inserts and penetration installation

with manually handling.

4. This invention is also applicable for

installation of inserts and penetrations on

board, e.g. louvers and coaming

Intangible Benefits

� Reduce risk of hand injury during window installation onboard.

� Eliminate any injury caused by using grinder or performing welding

operations.

� Increase work productivity, create more job satisfaction.

Results Achievement


� Increase work productivity, create more job satisfaction.

� Improve workers’ skill level through the integration of One-Man-

Operations concept.

� This major outward change in hull fitting process continues to

emphasis to employees on the importance of a strong safety culture

through continuous improvements.

Standardization

� The new process has been approved by management and implemented.

� The new process has been standardized and documented in Standard

Working Procedure.

� The training session has been conducted, and the workers have been


� The training session has been conducted, and the workers have been

briefed and evaluated on safe use of this window installation jig.

� The qualified workers have been granted by OMO training certification.

� The jig has been fabricated and equipped to window installation teams.

Review & Sustenance

Further Improvement


The clamping system is able to face in different direction to suitable able

in variable installation situation.

Review & Sustenance

Further Improvement

Turnbuckle retreat


Turnbuckle extend

• The adjusting system is able to provide a incline stance

• Suitable for incline side shell window installation

Review & Sustenance

Further Improvement

- 20 degree +20 degree


It is able to provide ±20 degree incline

Review & Sustenance

Further Improvement


Plumb-line for incline degree measurement

Review & Sustenance

The team’s next project will focus on hull block assembly fitting process. It

causes most manual handling hazard in the ship yard workshop.

Team’s Next Project


� The current window installation process eliminates the risk of hot work through the use of a unique jig.

� The design of this jig provides the platform to reduce the risk of hand related injuries during the fitting of window installation onboard.

Conclusion


� The jig has been fabricated and equipped to window installation team.

� To date, it has proven to be a well designed jig with no safety issue.

� The invention of this jig has help to reduce injuries and raised the morale of the employees.

Thank You


Question & Answer

Date post:	30-Dec-2016
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ST Marine - Improvement Process For Vessel Windows Installation

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