WHITEPAPER

IMPROVING WORK CONDITIONS in the field of a TRACK WORKER

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IMPROVING WORK CONDITIONS in the field of a TRACK WORKER

IntroductionIt’s a common question across the Rail infra industry: How can we streamline the process for increasing productivity, improving usability and creating better working conditions?

Today’s infra construction companies are looking for a faster, easier way to complete intensive projects. Enabling track workers and staff to manage their existing volume of work and handle the equipment, respecting current legislation.

This white paper explains how organizations can use the sustainable solution: “lightweight crane mounted in a container” from Firmus Solutions, to streamline the production process.

Maintaining and building railroad/track take place with help of heavy special equipment. This special equipment weighs often more than 50kg and should therefore not be lifted with muscle power. The Dutch legislation defines that one person is not allowed to lift more then 23 kg. A maximum of 2 persons is allowed to lift items together. Construction companies uses standard containers to transport the equipment to the project location. The weight of the equipment and its volume, causes heavy working conditions during loading and unloading of the transport container. It also results in an inefficient filling of the container (the equipment can not be stacked).

Reducing the weight of track equipment is challenging, and in most cases, not feasible. See picture 1 and 2 for an example.

Picture 1 – weight: 135kg Picture 2 – weight: 100kg

During the preparation phase of a project, in most cases this equipment will be gathered in the storage warehouse and positioned in a container with help of a forklift. Depending on the amount of required equipment, multiple containers are necessary if no space on the floor is available. The containers will be transported to the project location. These containers are dropped in a field regularly, far away from the working area. The problem occurs that no forklift or other helping device is available to get this equipment out of the container. Not spoken about the fact that in most cases the hindmost placed equipment is needed first. See picture 3 for the general process.

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Picture 3:Process flow equipment

This paper discusses optimization challenges and proposes cost-effective, secure and user-friendly solution on the areas A, B & C. See picture 3 for the overview.

The need for workflow optimization and creating helping devicesA few aspects are to be taken into account:

§ Experience shows that investments, only for improving usability/sustainability, are difficult to achieve.

§ The solution should be:o user-friendlyo have more advantages than only solving the lifting problem in the containero A positive ROI:

§ Projects can be stopped when Legislation will not be respected during the operation

§ Companies can gain “points” winning projects/tenders when they implement sustainable solutions.

Sustainable ideas often fail in decision process, because money has to be dedicated

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Performance and productivitySustainability is a known subject, but in many cases difficult to implement in organizations. Without performance enhancements, submitted sustainable ideas often fail in the decision process, because there is money to be dedicated. In addition, proposals are often not feasible because there is no support in the executive production staff. It often helps when the organization can see, feel and try out the solution/proposal before the potential solution is incorporated in the organization.

We can identify three places in the process where are possibilities for efficiency optimization:A. The equipment is placed on the floor of the container. When the floor is filled, a new

container will be used B. The containers are transported by truck to the project site. There is a maximum of 2

containers per transport.C. The heavy equipment need to be lifted manually in and out of container

Ad A Placing equipment on the floor of the containerIn the current process the floor of the container is loaded as efficiently as possible. When there is no more space available, the next container is filled. Through not stacking of the equipment, the occupancy of the container is not optimally used. If possible the equipment needed first in the process will be loaded in the front of the container.

Possible saving: Stacking equipment - less containers are needed. Depending on container layout - with or without walking aisle.

Picture 4: current filling degree container Picture 5: possible filling degree

Containers are used inefficiently at the moment, creating unnecessary container and transporting costs.

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Ad C The heavy equipment need to be lifted manually in and out of container.

Picture 5: Available tools to lift equipment in and out of container.

General specifications

• Aiding tool needs to be simple in nature.• Aiding tool needs to make it possible to move equipment stacked at the back to be

moved efficiently, quickly in an ARBO friendly way without removing or shifting other equipment (not applicable for stacked equipment)

• Possibility for stacking equipment by using scaffold pallet• loading and unloading should take place by 1 person

See pictures 6 and 7 for two examples.

Picture 6: option 1

Picture 7: option 2

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Solutions

1. Lifting tool by applying column with hinged jib

Picture 8: Sketch hinged jib

Advantages: Disadvantages:

Relatively cheap Difficult to disassemble - through which each container needs to be adjusted.

Larger range/reach outside the container Through articulated arm construction and point load on column not or less applicable/suitable for heavy loads.

Less or not suitable for stacking equipment.

Expensive if this aiding lifting tool needs to be implemented in every container.

Only solution to apply current ARBO legislation - No improvement for efficiency.

“Black spots” - no 100% reach (see picture 8)

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2. Lifting tool with guide rails.

Picture 9: lightweight overhead crane (old version!)

Advantages: Disadvantages:

Relatively cheap if possible saving methods are optimally used.

Higher unit price.

Applicable/suitable to stack equipment. Less range/reach outside the container - but enough to lift and move the equipment out of the container.

Applicable for load up to max. 500 kg.

Relatively easy detachable and mountable, through which only used containers need to be equipped with this aiding lifting tool (“rent article”).

Maximum reach in X, Y and Z-direction.

Maximum lifting height created by high placed lifting point.

TTackle available in electric version as well as manual version.

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The Financial Benefits of a lightweight crane in containerUp to 50% ROI in 4 years, Break-even in 3 years

The return on investment (ROI) analysis provided in this white paper only takesinto account the direct and inventory costs associated with using the lightweight crane in a container. The additional benefits of being able to respect legislation or time benefits (efficiency by faster load/unload container) has not been included in this analysis.

All estimates presented are hypothetical and meant for illustrative business purposes only. Individual results may vary depending on circumstances.

Three years analysesThree years analysesThree years analysesThree years analysesThree years analysesThree years analyses

Lightweight crane costs Start up Year 1 Year 2 Year 3 Total

Investment crane € 8.000- € 8.000-

Investment scaffold pallets 12 x € 140,- € 1.680-

Investment traverse € 1.000-

Annual Maintenance crane & traverse

- - € 200- € 200-

Annual Maint. pallets - - € 300- € 300-

Total Project costs € 10.680- € 500- € 11.180-

Benefits transport costs (1) € 4.200- € 4.200- € 4.200- € 12.600-

Financial Analyses

Net Value (2) € - 10.680- € - 6.480- € -2.280- € 1.420-

Financial Benefits of using lightweight crane in containerFinancial Benefits of using lightweight crane in container

ROI (1 year) -60%

ROI (3 year) 13%

ROI (5 years) 88%

Payback period: within 3 years

(1) Assumptions: • costs 1 transport container(s) to projectlocation: € 700,- • costs 1 transport container(s) back to warehouse: € 700,-• number ofprojects each year: 3• current situation (IST): 2 containers required for each project• future situation (SOLL): 1 container for each project, 6 pallets on floor, 6 pallets stacked

" Calculation: € 700,- x 2 x 3 = € 4.200,-(2) Positive amount of money = costs; Negative amount of money = benefit

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Conclusion

Fitting working conditions are important requirements for performing/working in a healthy and save way. Employees have to be anabled to perform their jobs without facing physically or mentally possible problems.

Employees are entitled to a save and healthy work place. This right is anchored in the health and safety law (Arbowet). The responsibility to create a working environment which meet these required (law) conditions is primarily a responsibility of the employer. The employer also has to ensure that the target conditions have to be achieved. How to achieve these target conditions is up to the emplyer.

The lightweight crane mounted in container can help improving the working conditions of track workers and can help generate significant financial benefits compared with current process. According to cost-benefit analysis, the lightweight crane has a payback period from approx. 2 years. When the scaffold pallets are also used in warehouse, investments for storage racks in the warehouse can be reduced.

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