WQD2011 - INNOVATION - EMAL - 3 Wheel Personal Carrier Modifications


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Innovation case study submitted by Emirates Aluminium during 3rd Continual Improvement & Innovation Symposium organized by Dubai Quality Group's Continual Improvement Subgroup to celebrate World Quality Day 2011.

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WQD2011 - INNOVATION - EMAL - 3 Wheel Personal Carrier Modifications

  1. 1. 3 Wheel Personal Carrier Modifications (Suggestion ID: - 6992) PL-2
  2. 2. Problem statement:1. Pot Lines are facing several and serious incidents - accidents while using a 3 Wheel PC.2. The problem is a 3 Wheel PC is not stable enough while moving in a sharp curve/turn.3. This abnormality has leaded to >5 recorded accidents including shoulder dislocation in Pot lines as well as other departments.4. The purpose of our idea is to eliminate the 3 Wheel PC incidents - accidents reoccurrence. 2
  3. 3. Usage of 3 Wheel PC in Pot Lines: -1. This mobile equipment is very useful in Pot Line as the total length is 1.3 km x 2 Rooms .2. Most of the time, Shift Supervisor or Sr. Technician needs to use this equipment for managing manpower distribution across the line, principally in Summer period.3. Every PC can be driven at least 5 to 6 hours/ shift and can travel more than 10kms/shift. 3
  4. 4. 3 Wheel PC Situation Before Modification 4
  5. 5. Suggestion ID: - 6992 Name of the Employees who have given the Suggestions1. Dilip Shankaran (Emp. No. 0584) PG 72. Mohd. Sohil (Emp. No. 1263) PG 73. Marcos Antonio (Emp. No. 2003) PG 5 5
  6. 6. Proposed 3 Wheel Personal Carrier Modifications1. Provide Safety guard for both side of the PC.2. Provide one seat for passenger in the back side.3. Provide seat belt for PC driver & back seat passenger. 6
  7. 7. 3 Wheel PC, Situation Before Modification 7
  8. 8. Modifications 8
  9. 9. Safe guard added in the original design 9
  10. 10. Back seat added in the original design 10
  11. 11. 1- Uniqueness of our idea:The original design was allowing to carrying 2 people without safe guard;we did in-house home work for improving safety condition along with thismobile equipment, it was never done before.2- TangibleEvery body (including engineering, Mobile fleet, EHS, operations and thesupplier) agreed that these modifications will add significant EHS benefits.It used to being not so easy task to align this percentage of positiveopinions.3- IntangibleThis mobile equipment is indispensable in pot line as people need to movefrom one end to other once or twice a day in a very difficult environment asyou are all aware. 11
  12. 12. 5- Simplicity Cost in $ Back Seat $ 372.75Safety belt $ 350.00Safety guard $ 54.50 man Hr $ 490.46 Total/Unit 1,267.71 12
  13. 13. EHS Benefits: -1. Personnel seating comfortably.2. Eliminate incident and accidents reoccurrence .3. Both passenger and driver have back restraint.4. Back seat passenger having proper holding place.5. Finally very good ergonomic conditions, our employees are happy with it 13
  14. 14. ImplementationSI SPA Start date End date ProgreNo Action ss1 Install safe guard on 1 PC in N.Joseph/ Abdulla 17/6/2011 20/06/2011 100% PL-2 Marwan2 Purchasing and Installing AJay 21/06/2011 30/06/2011 100% back seat2 obtaining approval from safety N.Joseph/ Abdulla 21/06/2011 30/06/2011 100% and engineering3 Obtaining approval from the AJay 01/07/2011 15/07/2011 100% supplier4 Installing safety guard for all N.Joseph/ Abdulla 16/07/2011 25/07/2011 100% units5 Full Design approval by N.Joseph/ Abdulla 20/08/2011 15/09/2011 100% management and EHS Soud/Praba5 Implementation of seat belt + AJay 20/09/2011 31/10/2011 20% back 14
  15. 15. Personnel are moving with full happiness from one location to another safely.Since implementation started in Pot Line 2 no more incident occurred. 15
  16. 16. 3 Wheel PC modification process:1. All these modifications are proposed and done in house in collaborate with CMS and Mobile Fleet Dept .2. Thanks very much to CMS and Engineering for approving the design.3. Thanks very much to Mobile fleet Dept. (who got validation from the supplier). 16
  17. 17. Safety Flash for last incidentsIncident: -Employees fell from a 3 Wheeler PC on theground resulting in injuries to his leftshoulder.Incident Details: -Mr. James (EM-2105) was sitting on back ofPC-50220 driven by Technician Mr. Satrujit(EM-1654), the rear seat of pc was not downand James was holding on to the beacon lightrod of the PC. While turning Mr. James lost hiscontrol and fell on ground. He complained ofpain on his left shoulder after falling.Preliminary Root Cause: -1. Seat was not down.2. Sharp Turning. 17
  18. 18. EHS Dept. E-mail for all Concern Dept. ManagersAn Incident occurred on 29.08.2011 as employee fell from the back seat of 3 wheelPC and injured his left shoulder.During the meeting with the department Managers, it is decided to STOP allowing passengerson back seat of 3 PC until Providing the protection Guard to back seat passengerto prevent reoccurrence of such incidents. Non compliance to the above should betreated as a SAFETY VIOLATION against the driver and Passenger.CMS is already commenced the modifications. Kindly schedule the 3wheel PC in your area forthe modification.Please communicate the above information to all PC users in your Area. This is a proof that the idea is shared by EHS department 18
  19. 19. Thank You for your attention 19