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Final2017
- 1. Establishment Of Accident Free ProductionArea Welcomes You To 1
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- 5. Ashish Rakshit Debdeep Bhattacharjee Swapan Mondal SushmitaDutt Emamun Ali Sha Aritro Das 5
- 6. STEP 1: Identification OfProblem 6
- 7. A • Failure ofinjection 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 7
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- 9. STEP 2: Selection OfProblem 9
- 10. Problems Pre determinedcriteria 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 Platens 1 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 10
- 11. 0 1 23 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Number of accidents Problemnumber 11
- 12. Sl. No ProblemsFrequency Percentage 1 Injuries during mould handling 8 34.78 2 Accidents during machine maintenance 5 21.74 3 Suspended particulate matter and flyaway 4 17.39 4 Equipment damage due to voltage fluctuations 4 17.39 5 Live circuit in contact with equipment body 1 4.35 6 Leakage of Hydraulic oil 1 4.35 7 Fire hazards 0 0 TOTAL 23 100 12
- 13. 0 10 20 30 40 50 60 70 80 90 100 0 1 2 3 4 5 6 7 8 Injuries during mould transport andstorage Accidents during mould maintainence Suspended particulate matter and flyaway Equipment damage due to voltage fluctuations Live circuit in contact with equipment body Leakage of Hydrolic oil Fire hazards Frequency Cum Freq 13
- 14. STEP 3: Defining TheProblems 14
- 15. Problem 1 • Injuriesduring 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 15
- 16. Production is carried out Maintenance is carried out Control panelis 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 Cutting machine is switched off Problem 2 • Accidents during machine maintenance– control panel maintenance of injection machine, grinding machine maintenance. 16
- 17. The plastic granules are stored Theplastic 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 17
- 18. Production is carried out Machine is operated Electrical supplyis switched on Problem 4 • Equipment damage due to voltage fluctuations – Spikes in voltage may damage the machine 18
- 19. S.no Activity ResponsibilityOct’ 16 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 19
- 20. STEP 4: Analyze TheProblem 20
- 21. What is theproblem? 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 21
- 22. What is theproblem? 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 22
- 23. What is theproblem? 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
- 24. What is theproblem? 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 24
- 25. STEP 5: Identification OfCauses 25
- 26. Injuries during Mould Handling Protective gearnot used Loose parts falling off from moulds EOT crane break failure Protective gear not provided 26
- 27. Injuries during Machine Maintenance Protective gear notused LOTO not implemented Human error during machine maintenance Protective gear not provided Failure of Limit Switch 27
- 28. Suspended Particulate Matters and Flyaway Protectivegear not provided Protective gear not used 28
- 29. Equipment Damage due tovoltage fluctuations Voltage stabilizer not provided 29
- 30. STEP 6: Finding OutRoot Causes 30
- 31. EOT crane failure Irregular maintenance Loose parts fallingfrom mould Checks on mould not performed before transport 31
- 32. Power supply switched on accidentally Lackof attention of Operators/Human error 32
- 33. Injuries due to Suspended particulate matter Protectiveeye gear and gloves not used Absence of safety measures 33
- 34. Fluctuations in power supply Absenceof Power stabilizer 34
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- 36. 0 10 20 30 40 50 60 70 80 90 100 0 1 2 3 4 5 6 7 8 Injuries during mould transport andstorage Accidents during mould maintainence Suspended particulate matter and flyaway Equipment damage due to voltage fluctuations Live circuit in contact with equipment body Leakage of Hydrolic oil Fire hazards Frequency Cum Freq 36
- 37. • Brain storming •Data Collection • PDCA STEP 8: Developing Solutions 37
- 38. Provide workers with Safety helmets, Industrialboots and safety harness Making sure that the mould to be transported has no loose parts Routine EOT Crane maintenance Problem 1 38
- 39. Implementation of LOTO Providing Rubber mats andgloves to prevent electrical shocks Providing safety eye gear during machine maintenance Problem 2 39
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- 42. STEP 9: Foreseeing ProblemsOf Resistance Fund allocation from management Periodic training and safety drill implementation Providing SOP's for machine operation Enforcing strict safety measures and providing incentives 42
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- 44. Regular checks areconducted to ensure compliance with safety regulations. Periodic drills conducted and attendance of employees is monitored. Routine maintenance checks for machinery and components. 44
- 45. • To providea 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 45
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- 47. 0 1 2 3 4 5 6 7 8 Problem 1 Problem2 Problem 3 Problem 4 47
- 48. • Minimized PropertyDamage • Reduction of machine downtime • Increased financial savings • Efficient use of available man-power • Increased employee morale • Safer working environment • Job satisfaction for employees 48
- 49. STEP 12: Follow UpAnd Review 49
- 50. Step No. ActivityResponsibilities Oct'16 Nov'16 Dec'16 3 Defining the Problem All Members Target Achieved 4 Analysis of the problem All Members Target Achieved 5 Identifying the causes All Members Target Achieved 6 Finding out the root causes All Members Target Achieved 7 Data Analysis A.Rakshit & S.Mondal Target Achieved 8 Developing Solution All Members Target Achieved 9 Foreseeing Resistance All Members Target Achieved 10 Trial Implementation S.Mondal & C.Das Target Achieved 11 Regular Implementation All Members Target Achieved 12 Follow up/Review S.Mondal & C.Das Target 50
- 51. But, We do have onemore thing! f f 51
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- 55. For the nextproject we will be working on: 55
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