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SMa – WSHi Award 2007

GE Aviation Service Operation LLP

Minimize Time Needed To Clear Sludge Pit At Mechanical Clean

Room

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GE Aviation Service Operation LLP (GEASO) provides state-of-art jet engine component repair services, which are defect-free, delivered on time and in a boundaryless, safe, healthy and motivated work environment while complying with all government regulations and GE policies.

GEASO was the first GE site in Asia to achieve Global Star Award which is equivalent to OSHA’s Voluntary Protection Program (VPP) in 1999 and was subsequently recertified in 2004.

Beside the various EHS awards received from GE Engine Services, we are actively involved in Noise Control, Chemical Best Practice Award and Workplace Safety And Health Innovation Award by Ministry of Manpower.

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PARTICULARS OF TEAM Facilitator : Lim Chiap Jway (Facility and EHS Leader) Leader : Chia Yeong Ming, Samon (EHS Engineer) Members : Lim Hong Kwang (Facility Engineer)

Lim Tow Nan (EHS Engineer)  Paul (Janitor Supervisor)

Mohammed Ayub (Janitor)

  Raymond Choy (Waste Water Treatment Plant Technician)

Lew Eng Choon (Black Belt)  BACKGROUND INFORMATION OF THE TEAM  Team was formed in July 2005 as it was observed that Janitor spent an average of 100.2 hours annually to manually clear the sludge in the Mechanical Clean Room where 81% of the total sludge in the plant was generated. Each sludge clearing process would require the janitor to use a hand held scoop to transfer the sludge from the pit into plastic bags which were then wheeled to the WWTP that was situated at 40 meter away. While clearing the sludge, janitor faced with the repetitive bending and stress on lower back and arms. Through brain storming and evaluating of various options, the team came up with an automated pumping system and put it into operation in February 2006.

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PROJECT SELECTION & DEFINITION

Sludge is a by-product of cleaning and polishing processes during the repair of the jet engine components. A study within the plant revealed that 81% of the total sludge produced was from the Mechanical Clean Room (MCR) with remaining 19.4% and 6.5% from the Chemical Clean Room (CCR) and Waste Water Treatment Plant (WWTP) respectively. The total time taken for clearing the sludge at MCR was averaged at 100.2hrs annually and the EHS concerns faced by the Janitor cannot be ignored.

81.0 % 19.4 % 6.5 %

CCR24 hrs

MCR100.2 hrs

WWTP8 hrs

Time Taken to Clear Sludge Annually in GEASO

Area of focus

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JOB HAZARD ANALYSIS

Before the automatic pumping system was implemented, Job Hazard Analysis conducted in 2003 revealed the ergonomic risks involved with the manual clearance of sludge at the MCR. Please refer to the attached JHA worksheet.

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•The constant removal and replacing the pit covers were the other challenges faced by the Janitor due to the weight and the possibility of pinching their fingers between the cover and the ground.

•Janitor was likely to expose to noise (Hearing Protection Zone) when clearing of the sludge.

JOB HAZARD ANALYSIS

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AREAS FOR IMPROVEMENT The old process are as followed;

NEED TO ELIMINATE THE ERGOMONIC, SAFETY & HEALTH CONCERNS AT STEP 4 AND 5.

Step1. Sludge produced from the tumblers

and wet blast machine, flows to collection pit.

Step 2.Janitor cordon surrounding area

sludge collection pit

Step 3.Janitor manually removing the

cover for the collection pit.

Step 4.Manually removing sludge from pit

using an extended scoop and placing sludge into plastic bags.

Step 5. Janitor pushes trolley with bags filled with sludge to the wastewater treatment plant,

leaving pit open.

Step 6. Process repeated till

all sludge from pit removed and

collection pit was covered.

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ANALYTICAL TECHNIQUES

MACHINES/ EQUIPMENT

METHODS

Manual Clearing of

Sludge

ENVIRONMENT

Solidification of sludge at

the holding pit

CAUSE & EFFECT

Tumblers constantly producing

waste water & residue to the collection pit

Original design of collection

pit

Manual Operation

Average of 80 kg of sludge

produced weekly

MAN

Single person tasked to do the

job

Pit is 1.2 meter deep

MEASUREMENT

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CORRECTION ACTIONS & IMPLEMENTATION

After brainstorming, the team was able to provide two feasible solutions, i.e., to use a vacuum or automatic pumping system. Disadvantage of the vacuum equipment was costly, pit covers still required to be lifted and sludge needed to be transferred to the Waste Water Treatment Plant. In long term, the vacuum system would be difficult to maintain as well.

The automatic pumping system was then chosen as it was easy to fabricate in-house, cost effective and easy to operate with minimal maintenance effort. However, the team was still faced with the pumping of solidified sludge within the pit.

With further brain storming, the team decided to overcome this problem by installing a compressed air piping at the bottom of the pit to loosen the sludge. The compressed air would be activated by a level switch when the sludge reached a pre-determined level in the pit. A timer was also incorporated to start the sludge pumping process at an appropriate time. The liqufied sludge were then pumped directly to the Waste Water Treatment Plant.

The automatic system was installed and tested in late November 2005 and fully commissioned and operational in February 2006.

ISSUES

• Original design of the collection pit.

• Solidification of sludge at the holding pit.

• Manual operation.

Solution

(1) Using vacuum to suck sludge.

Pro/ Cons

• Costly to source for right machines.

• Still need to transfer sludge to WWTP.

• Difficulty in maintaining system.

(2) Automatic pumping system.

• Minimum cost to install.

• Minimum alteration to existing system.

• Tremendous benefits in EHS and time reductions.

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s

TO SLUDGE TREATMENTSYS.

TO SLUDGE TREATMENTSYS.

COMPRESSED AIR AGITATOR

DIS-USED PIT

SLUDGE SEDIMENT

PIT

SLUDGEWATER PIT

SLUDGE INLET

SLUDGE INLET

TIMER / SOLENOID VALVE

COMPRESSED INLET

BEFORE IMPROVEMENTMANUAL SLUDGE CLEARING SYSTEM

AFTER IMPROVEMENT AUTO SLUDGE CLEARING SYSTEM

INSTALLATION COST US$ 600

DISCHARGE PUMP

DISCHARGE PUMP

LEVEL SWITCH

SLUDGE

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AFTER IMPLEMENTATION

After implementing the automatic sludge pumping system, the manual clearing process by the janitor was eliminated, it also reduce the opportunity for janitor to be exposed to noise and chemical in MCR.

PREVENTIVE MAINTENANCE & INSPECTION ARE NOW DONE ON A MONTHLY BASIS

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Risk Abatement

Pump failure.

Timer failure.

Compressed air failure.

Comprehensive preventive maintenance program with emphasizing on the pump, timer and compressed air system. (Refer to next slide)

Mishandling of the system.

Training provided for designated janitor/ WWTP Technician for the automated system.

Only trained janitor/ authorized person is allow to handle/operate the system.

Random inspection by janitor’s supervisor, and EHS/FAC engineers to ensure works are carried out in a safe manner.

Potential injuries due to opening and closing of the pit cover during PM.

Provide training for designated janitor/ GEASO CRT on how to reduce injuries.

Safety risk assessment communicated to the WWTP technician and Janitor

Provide barricade whenever pit cover is open.

STANDARDIZATION, DOCUMENTATION & MAINTENANCE

Risk of Automatic Pumping System failing were identified and abatements incorporated.

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MAINTENANCE OF NEW PROCEDURE

Monthly checklist for Effluent Treatment Plant includes checking of the air tubing and timer. WWTP and Janitor continue to ensure that system is in good working condition. Facility and EHS engineers conduct random inspection at MCR to ensure that automatic pumping system is maintain and working well.

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RESULTS ACHIEVED

Tangible Results : Average time (Annual) saved due to automation is 92 hours. Average saving material cost is US$221 annually.

Intangible Results : Elimination of Ergonomic risksElimination of safety related issues.High morale among Janitor and employees

Cost of modification : US$600

Automatic Pumping System Innovative way to reduce the risks faced

by janitor

Positive air tap from existing source and

additional timer installed

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TEAM NEXT PROJECTS

Various EHS projects are in the pipelines;• Noise reduction for Grit Blast & VTL machines.• Replacing wire ropes with pneumatic cylinders to reduce potential injuries to hand/ arm.• Eliminating ergonomic risk to arm by replacing manual operated press with hydraulic press.• Mass Hand Safety Exercise view through Video Clip from the work cells desktops to raise hand safety awareness among the workforce.

CONCLUSION

By using innovative engineering means, the automated pumping system eliminates the ergonomic, health and safety risks and increase the morale among both GE Employees and contractor.

As a responsible organization, GE Aviation Service Operation LLP (GEASO) constantly looks into feasible and sustainable solutions to reduce and eliminate EHS concerns faced by employees and contractors working within GEASO.

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