Innovations in Working Safely at Heights - Workplace Safety and ...
Innovations in Working Safely at Heights - Workplace Safety and ...
Innovations in Working Safely at Heights - Workplace Safety and ...
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The Corpor<strong>at</strong>e HSE Culture...1. At Cameron, HSE is the core value of our bus<strong>in</strong>ess.2. HSE is on the top of agenda across the board, from CEO down to shoppersonnel3. Cameron uses Global <strong>in</strong>tranet based HSE management system4. All <strong>in</strong>cidents, <strong>in</strong>clud<strong>in</strong>g near misses are reported through the <strong>in</strong>tranet MS systemTo Ultim<strong>at</strong>ely Achieve:5
Cameron HSE Management System1. Structure <strong>and</strong> Responsibility2. Objectives3. Consult<strong>at</strong>ions & Communic<strong>at</strong>ion4. Document <strong>and</strong> D<strong>at</strong>a Control5. Legal <strong>and</strong> Other Requirements6. Tra<strong>in</strong><strong>in</strong>g, Awareness <strong>and</strong> Competency7. …. 18
Valve Assembly1. Clean<strong>in</strong>g ComponentsLegend 图 例Poor Work<strong>in</strong>gPosture不 良 的 工 作 姿 势ChemicalInhal<strong>at</strong>ion化 学 品 吸 入Chemical Contact化 学 品 接 触• Key oper<strong>at</strong>ions have a HRA• Jo<strong>in</strong>tly assessed by HSE team, Shopmanagement & Technicians• Regularly reviewed <strong>and</strong> upd<strong>at</strong>edNO ONE GETS HURT, NOTHING GETS HARMED9HRA #8234WI-A&TA&T-01Drop Object掉 落 的 物 体Trip & Fall绊 脚Flammable易 燃 物DRILLING & PRODUCTION SYSTEMS
Accident/Injury Report<strong>in</strong>g All accidents <strong>and</strong> <strong>in</strong>juries(<strong>in</strong>clud<strong>in</strong>g near misses) arereported with<strong>in</strong> 24 hours thruthe <strong>in</strong>tranet based HSE MSsystem The respective departmentwill <strong>in</strong>vestig<strong>at</strong>e the root causes<strong>and</strong> come up with corrective<strong>and</strong> preventive actions The HSE Team performsevalu<strong>at</strong>ion <strong>and</strong> monitorseffectiveness of theimplement<strong>at</strong>ions10
Prevent<strong>at</strong>ive Approaches1. Suggestions Scheme One suggestion per employee permonth Capture the potential risk before ithappensNO ONE GETS HURT, NOTHING GETS HARMED11DRILLING & PRODUCTION SYSTEMS
Prevent<strong>at</strong>ive ApproachesBBSP Checklist1. Suggestions Scheme2. Behavior Based <strong>Safety</strong>ProcessWh<strong>at</strong>? – an observ<strong>at</strong>ion & feedback processWhen? – dur<strong>in</strong>g normal work activitiesWhere? – <strong>in</strong> the workplaceWhy? – to improve workplace safetyHow? – by focus<strong>in</strong>g on observable actsWho? – by employees
Importance of BBSP
Prevent<strong>at</strong>ive Approaches1. Suggestions Scheme:2. Behavior Based <strong>Safety</strong>Process3. Step Back 5 by 5Step Back 5x5 – Cont<strong>in</strong>ual RiskHazards – Wh<strong>at</strong> If?HAZARD IDENTIFICATIONWh<strong>at</strong> Could Go Wrong?4 – Why?HAZARDOUS EVENTSWhy would releases of, or contactwith, hazardous energyoccur (i.e. be caused <strong>and</strong> haveharmful consequences)?Assessment & ControlRisk AssessmentRisks – So Wh<strong>at</strong>?RISK ANALYSIS &EVALUATIONWh<strong>at</strong> Are the Chances ofHarm?5 – When?LEVELS OF RISKSWhen is it safe (i.e. acceptable)to work, based on the estim<strong>at</strong>edControls – Then Wh<strong>at</strong>?RISK REDUCTIONWh<strong>at</strong> Must I Do to Prevent or Mitig<strong>at</strong>eHarm?6 – How?ELIMINATIONHow can I elim<strong>in</strong><strong>at</strong>ethe source of theRisk Control7 – How?SUBSTITUTIONHow can I substitutea less hazardousseverity & likelihood of harmhazardous energyenergy source or(i.e. risk)? or the job task ? job task? Stop Evalu<strong>at</strong>e Act Work <strong>Safely</strong>3 – Who?HAZARDOUS SITUATIONSWho is exposedto hazardous energy(i.e. be<strong>in</strong>g In Harm’s Way)?2 – Where?HAZARD ZONESWhere are the flow p<strong>at</strong>hsof hazardous energy(i.e. Harm’s Way)?1 – Wh<strong>at</strong>?HAZARD SOURCESWh<strong>at</strong> are the types <strong>and</strong> sources ofstored <strong>and</strong> flow<strong>in</strong>g hazardous energy?5 5X8 – How?ENGINEERING CONTROLSHow can I conta<strong>in</strong> or control therelease of, or contact with,hazardous energy?9 – How?ADMINISTRATIVE CONTROLSHow can I control the quality ofwork processes to m<strong>in</strong>imize theharm of hazardous events?10 – How?PERSONAL PROTECTIVEEQUIPMENT (PPE)How can I protect myself?NO ONE GETS HURT, NOTHING GETS HARMED14DRILLING & PRODUCTION SYSTEMS
Methodology - DMAICStep 5 – ControlWh<strong>at</strong> controls will keepthis process susta<strong>in</strong>able ?ControlLimitsStep 4 – ImproveWhich factors willchange <strong>and</strong> wh<strong>at</strong> arethe new control limits?Step 1 – Def<strong>in</strong>eWhich process to focus?CFactorsIDAMStep 3 – AnalyzeWhich factors contributeto potential dangers?ProcessStep 2 – MeasureWh<strong>at</strong> is the currentcondition?Condition
Team Name:Leaders:MAINTENANCETeo Ung Swee ( Manufactur<strong>in</strong>g Specialist)Pan Peim<strong>in</strong>g (Ma<strong>in</strong>tenance Eng<strong>in</strong>eer)Sng Kim Theow (Ma<strong>in</strong>tenance Lead)Team Members:Jimmy M De Jesus (Ma<strong>in</strong>tenance Lead)Jon<strong>at</strong>han Hu Y<strong>in</strong> Wei (Facility Technician)16
Def<strong>in</strong>eProject Def<strong>in</strong>itionCurrent Situ<strong>at</strong>ion• In the office, most of the light<strong>in</strong>gs are <strong>in</strong>stalled directly above the work<strong>in</strong>g st<strong>at</strong>ions(shown <strong>in</strong> below figure 1a).Light<strong>in</strong>gabove workdesk.Figure 1aFigure 1bNot forheavy load!!!• When there is a need to replace the light<strong>in</strong>gs, the Ma<strong>in</strong>tenance Facility Technician willneed to st<strong>and</strong> on the work desk to change the fluorescent tubes due to spacerestriction <strong>in</strong> us<strong>in</strong>g the ladder (refer to figure 1b). St<strong>and</strong><strong>in</strong>g on the work desk is quiteunsafe as it is not designed to c<strong>at</strong>er heavy load.17
MeasureProject Def<strong>in</strong>itionProject Objective <strong>and</strong> Theme• The project objective is to let the Ma<strong>in</strong>tenance-Facility Technician replace the light<strong>in</strong>gfluorescent tubes without st<strong>and</strong><strong>in</strong>g on the work desk (<strong>in</strong> safe <strong>and</strong> proper manner).• The theme of the project is to <strong>in</strong>crease the efficiency <strong>and</strong> productivity of the job to becarried out by reduc<strong>in</strong>g safety <strong>and</strong> health hazards.Risk Assessment before ImprovementHazard Identify – Technician fall<strong>in</strong>g off from work desk.Frequency – Probability of Occurrence<strong>Safety</strong> <strong>and</strong> HealthConstant5 (hourly)Frequent4 (daily)Occasional3 (weekly)Infrequent2 (monthly)Unlikely1 (yearly)Potential EffectF<strong>at</strong>ality 5 25 20 15 10 5Lost Time Accident 4 20 16 12 8 4Recordable 3 15 12 9 6 3First Aid 2 10 8 6 4 2Near Miss 1 5 4 3 2 118
AnalyzeAltern<strong>at</strong>ive for selectionAltern<strong>at</strong>ive Solutions with advantages <strong>and</strong>disadvantages.Altern<strong>at</strong>ive Solutions Advantages DisadvantagesS1. Reloc<strong>at</strong>ion of light<strong>in</strong>gsS2. Reloc<strong>at</strong>ion of work desk Easy accessibility of us<strong>in</strong>g ladderfor replac<strong>in</strong>g of the light<strong>in</strong>gs Easy accessibility of us<strong>in</strong>g ladderfor replac<strong>in</strong>g of the light<strong>in</strong>gs• Office lum<strong>in</strong>ous efficacy will beaffected.• Higher cost to relay wires.• Un-organized layout.• Distruption of work.• Higher cost <strong>in</strong>curred.S3. Design <strong>and</strong> fabric<strong>at</strong>e of specialstag<strong>in</strong>g Easy accessibility <strong>Safety</strong> Stability <strong>and</strong> user friendly• Higher cost.Selected Solution19
ImproveThe Selected Solution…S3. Design <strong>and</strong> fabric<strong>at</strong>ion ofspecial stag<strong>in</strong>gDesign Consider<strong>at</strong>ions:Lock<strong>in</strong>g mechanismRigid StructureAccessibilityUser friendlyErgonomicsThe C-Stag<strong>in</strong>g20
Improve<strong>Safety</strong> Fe<strong>at</strong>ures21
ImproveUs<strong>in</strong>g of The C-Stag<strong>in</strong>g Able to reach places th<strong>at</strong> are noteasily accessible by ladder tochange light<strong>in</strong>gs (refer to figure 2). Provide stable pl<strong>at</strong>form with thelock<strong>in</strong>g mechanism.Figure 222
ImproveRisk Assessment after Implement<strong>at</strong>ionAfter the implement<strong>at</strong>ion of The C-stag<strong>in</strong>g, a risk assessment is be<strong>in</strong>gconducted as shown <strong>in</strong> below table.A drop <strong>in</strong> the probability of occurrence to ‘UNLIKELY’ as compared to‘FREQUENT’ before the implement<strong>at</strong>ion.Frequency – Probability of Occurrence<strong>Safety</strong> <strong>and</strong> HealthConstant Frequent Occasional Infrequent Unlikely5 (hourly) 4 (daily) 3 (weekly) 2 (monthly) 1 (yearly)Potential EffectF<strong>at</strong>ality 5 25 20 15 10 5Lost Time Accident 4 20 16 12 8 4Recordable 3 15 12 9 6 3First Aid 2 10 8 6 4 2Near Miss 1 5 4 3 2 123
ControlWork Instruction for C-Stag<strong>in</strong>g24
Agenda:Cameron <strong>in</strong> BriefDivider graphic should fill <strong>and</strong> notexceed the def<strong>in</strong>ed gray box.HSE Culture & ChallengesThe Systemic & Prevent<strong>at</strong>iveApproachBenefits of Good HSE PracticesNO ONE GETS HURT, NOTHING GETS HARMED 25 DRILLING & PRODUCTION SYSTEMS
Benefits of Good HSE Practices1. HSE is the m<strong>in</strong>dset, expect<strong>at</strong>ion <strong>and</strong> the way we dobus<strong>in</strong>ess2. HSE st<strong>and</strong>ard reflects bus<strong>in</strong>ess st<strong>and</strong>ard3. Investment <strong>in</strong> HSE will be returned by better people morale better image <strong>in</strong> the community improved bus<strong>in</strong>ess bottom l<strong>in</strong>e26
Optimiz<strong>in</strong>g Manufactur<strong>in</strong>g ProcessesThrough Lean Six SigmaA&T Flow ImprovementBeforeLean, Visual ShopsProcess FlowCycle ReductionCost ReductionCustomerExperienceHouse Keep<strong>in</strong>gHSSELean, Visual ShopRe-layout A&T shop for better flowInvested US$2m for power torque toolsfor better <strong>and</strong> safer oper<strong>at</strong>ionsInvested US$3m for fully enclosed testbunkers for safety <strong>and</strong> productivity(multiple parts test<strong>in</strong>g)AfterEnd Results: Through put has <strong>in</strong>creased by 30%
Plan Once, Execute to Plan100% Through MRP100.0%95.0%90.0%Cameron S<strong>in</strong>gaporeOn Time Delivery94.7% 95.7% 96.5%98.1%85.0%80.0%75.0%70.0%65.0%60.0%55.0%50.0%2009 2010 2011 2012 YTDPlann<strong>in</strong>g Through SAP-MRPTender: Knows wh<strong>at</strong> to offer1. DRF process:2. Perform load simul<strong>at</strong>ion for major tenders <strong>and</strong>determ<strong>in</strong>e the b<strong>at</strong>ch deliveryKey: Ma<strong>in</strong>ta<strong>in</strong><strong>in</strong>g accur<strong>at</strong>e master lead time for m<strong>at</strong>erials <strong>and</strong>manufactur<strong>in</strong>g.Turns Order: 100% MRP Plann<strong>in</strong>g1. Revalid<strong>at</strong>e Load/Capacity2. Run MRP Schedul<strong>in</strong>gExecution: Plan Ahead & Execute to Plan1. Plan mach<strong>in</strong>e load 3 months ahead: In House,B<strong>at</strong>am/CM <strong>and</strong> vendors2. Launch m<strong>at</strong>erials/production run per MRP schedule(open period)Putt<strong>in</strong>g It Together1. Plan A&T load 3 months ahead2. Launch assembly & tests us<strong>in</strong>g MTO collective3. Vessel book<strong>in</strong>g when parts past test<strong>in</strong>g <strong>and</strong> go<strong>in</strong>g forpa<strong>in</strong>t<strong>in</strong>g4. Trigger DN, Pack<strong>in</strong>g & follow through to GI process.
CheaperBetterFasterSaferBus<strong>in</strong>ess Bottom L<strong>in</strong>e <strong>and</strong> <strong>Safety</strong> comes h<strong>and</strong> <strong>in</strong>h<strong>and</strong>, with the <strong>in</strong>volvement of all !!
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