Semi-Auto Crimper Machine

Transcription

1 2018 WSH Innovation Awards (Manufacturing) Semi-Auto Crimper Machine GE Aviation Singapore Team

2 Contents Company Introduction Project Background Problem Statements Analytical Techniques Proposed Solutions Comparison & Selection of Solution Features of Selected Solution Results Achieved Conclusion June 3,

3 Company Introduction Global aircraft engine component repair & manufacturing facility Contributes >20% of GE s global footprint Serves >25 customers Plant 23 Plant 62 June 3,

4 Project Background Install honeycomb seal into vane sector and crimp J-Hook Main tools: Aluminum block and mallet Hammering force to crimp J-Hook on the vane sector Aluminum block Mallet Manual crimping June 3,

5 Problem Statements 15 ergonomic risk factors (moderate risk) Exposure to repeated impact from manual knocking Exposure to high noise at 91.0 dba Potential hand injury if mallet strikes the hand Potential flying object hazard Long cycle time June 3,

6 Problem Statements Negative feedbacks from technicians: a. Labor intensive Repetitive hammering b. Wrist killer High potential to cause wrist injury c. Neck breaker Prolonged neck bending forward June 3,

7 Analytical Techniques Ergonomic assessment tools: a. Video-based observational techniques To conduct ergonomic evaluation b. GE Ergonomic Risk Identification Form To identify ergonomic risk factor June 3,

8 June 3,

9 Proposed Solutions Proposed Solution 1 Pneumatic Crimper Leg-operated pneumatic crimper Manual rotation to crimp J-Hook segment by segment High noise Multiple pinch point hazards Labor intensive Long cycle time June 3,

10 Proposed Solutions Proposed Solution 2 Semi-Auto Crimper Machine Pneumatic force is converted into impact force to crimp J-Hook Crimp the entire arc length at once Set up fixture in the machine Load & secure part into the fixture Push-button to operate June 3,

11 Comparison & Selection of Solution Proposed Solution 1 Benefits Tick Pneumatic Crimper No more repetitive hammering motion Proposed Solution 2 Benefits Tick Semi-Auto Crimper Machine No more repetitive hammering motion No more strike by hammer hazard No more flying object hazard Reduce noise Simple and fast operation Semi-Auto Crimper Machine is SAFER & MORE COST EFFECTIVE June 3,

12 Features of Selected Solution Semi-Auto Crimper Machine Semi-automated process Fully enclosed in a noise reduction chamber 2-hand operation Door interlock system June 3,

13 June 3,

14 Results Achieved Tangible Results Eliminate repetitive hammering Eliminate strike by hammer hazard Eliminate flying object hazard Reduce ergonomics risk factors (15 to 4) Reduce noise level by 5 db Reduce labor hour by 60% per set Cost saving of $ 48,000 per year Reduce the risk of damaging the hardware Intangible Results Cultivate proactive safety mindset and behavior Enhance employee morale Promote innovative ideas to drive safety improvement Increase employees involvement to create safe working environment Improve organization s safety culture and safety performance June 3,

15 Conclusion Before Improvement Manual operation After Improvement Semi-Automated 15 risk factors 4 risk factors 90-minute Innovation Ergonomics Risk Reduction Noise Reduction 91.0 dba 86.0 dba Time Saving 30-minute June 3,

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