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.

1. 3 Wheel Personal Carrier
Modifications
(Suggestion ID: - 6992)
PL-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.
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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.
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4. 3 Wheel PC Situation Before Modification
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5. Suggestion ID: - 6992
Name of the Employees who
have given the Suggestions
1. Dilip Shankaran (Emp. No. 0584) PG 7
2. Mohd. Sohil (Emp. No. 1263) PG 7
3. Marcos Antonio (Emp. No. 2003) PG 5
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6. Proposed 3 Wheel Personal Carrier Modifications
1. 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.
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7. 3 Wheel PC, Situation Before
Modification
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8. Modifications
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9. Safe guard added in the original design
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10. Back seat added in the original design
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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 this
mobile equipment, it was never done before.
2- Tangible
Every body (including engineering, Mobile fleet, EHS, operations and the
supplier) agreed that these modifications will add significant EHS benefits.
It used to being not so easy task to align this percentage of positive
opinions.
3- Intangible
This mobile equipment is indispensable in pot line as people need to move
from one end to other once or twice a day in a very difficult environment as
you are all aware.
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12. 5- Simplicity
Cost in $
Back Seat $ 372.75
Safety belt $ 350.00
Safety guard $ 54.50
man Hr $ 490.46
Total/Unit 1,267.71
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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
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14. Implementation
SI SPA Start date End date Progre
No Action ss
1 Install safe guard on 1 PC in N.Joseph/ Abdulla 17/6/2011 20/06/2011 100%
PL-2 Marwan
2 Purchasing and Installing AJay 21/06/2011 30/06/2011 100%
back seat
2 obtaining approval from safety N.Joseph/ Abdulla 21/06/2011 30/06/2011 100%
and engineering
3 Obtaining approval from the AJay 01/07/2011 15/07/2011 100%
supplier
4 Installing safety guard for all N.Joseph/ Abdulla 16/07/2011 25/07/2011 100%
units
5 Full Design approval by N.Joseph/ Abdulla 20/08/2011 15/09/2011 100%
management and EHS Soud/Praba
5 Implementation of seat belt + AJay 20/09/2011 31/10/2011 20%
back
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15. Personnel are moving with full happiness from one location to another safely.
Since implementation started in Pot Line 2 no more incident occurred.
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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).
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17. Safety Flash for last incidents
Incident: -
Employees fell from a 3 Wheeler PC on the
ground resulting in injuries to his left
shoulder.
Incident Details: -
Mr. James (EM-2105) was sitting on back of
PC-50220 driven by Technician Mr. Satrujit
(EM-1654), the rear seat of pc was not down
and James was holding on to the beacon light
rod of the PC. While turning Mr. James lost his
control and fell on ground. He complained of
pain on his left shoulder after falling.
Preliminary Root Cause: -
1. Seat was not down.
2. Sharp Turning.
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18. EHS Dept. E-mail for all Concern Dept. Managers
An Incident occurred on 29.08.2011 as employee fell from the back seat of 3 wheel
PC and injured his left shoulder.
During the meeting with the department Managers, it is decided to STOP allowing passengers
on back seat of 3 PC until Providing the protection Guard to back seat passenger
to prevent reoccurrence of such incidents. Non compliance to the above should be
treated as a SAFETY VIOLATION against the driver and Passenger.
CMS is already commenced the modifications. Kindly schedule the 3wheel PC in your area for
the 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
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19. Thank You for your attention
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