The ShawCor Manufacturing System
The ShawCor Manufacturing System
The ShawCor Manufacturing System
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Kabil<br />
Kevlar<br />
Sleeve<br />
Hearing<br />
Protection<br />
Hand<br />
Foot<br />
Safety<br />
Gla ses<br />
Line:<br />
Hard<br />
Hat<br />
LATCH<br />
1<br />
Photo 6<br />
E-STOP<br />
Buzzer<br />
Photo 5<br />
Photo 7<br />
+<br />
Photo 8<br />
1G<br />
Photo 9<br />
M<br />
i<br />
Successful Plants<br />
• Have committed, supportive, and engaged leaders and support staff<br />
• Have demonstrated knowledge of SMS and sustain results<br />
• Have changed the way they work<br />
• Have demonstrated reliable and predictable performance<br />
• Are developing best practices for the organization to learn from<br />
• Have taken ownership & built local capability<br />
Reviewed and Approved by;<br />
QA Manager HSET Manager<br />
Operations Manager Plant Manager<br />
Dave Conroy<br />
Prasetyoadi Rab Wilson<br />
Alistair Salmond<br />
Indonesia<br />
Country:<br />
Plant:<br />
Rock Jacket<br />
Coating Rock Jacket<br />
SOP#<br />
Work Station<br />
Required PPE<br />
Activity & Seq. Operating<br />
Positions<br />
1 - Wire Prep 2 - Wire Latch (3)<br />
3 - Plant Operator<br />
4 - Supervisor<br />
5 -<br />
Raw Materials & Equipment: Wire Cutter, Shear, Wire Holding Rack with Shaft and Post, E-Stop, Buzzer<br />
Op No Main Steps Hazard/Non-Conformance<br />
Control Measure<br />
KP Reference Documents<br />
1,2,3,4,5 1<br />
Wire Mesh Feed<br />
RJ COATING RJ COATING RJ COATING RJ COATING RJ COATING RJ COATING RJ COATING RJ COATING RJ COATING RJ COATING RJ COATING RJ COATING<br />
Stay Clear from Forklift Path, adequate work<br />
Forklift delivers Wire Bundles from Storage to the Wire Station Area.<br />
5,4 1A Struck by Forklift or Wire Bundle<br />
space, adequate i lumination, authorised &<br />
Verify the Wire Gage or Specification with Supervisor<br />
trained operator, constant communication<br />
+<br />
between coworker<br />
Long Handle Shears, hand leather glove,<br />
Use Wire Cu ter, Cut Banding Strap to separate Individual Wire Ro ls Cuts/Laceration, struck by wire ro l,<br />
2 1B proper work position, constant communication<br />
from Bundle (Photo 1 on the background)<br />
trip/fa ling<br />
between coworker, fo low manual handling<br />
+<br />
procedure properly, team work<br />
2 1C Use Wire Cu ter, Cut Front Wire to form a Latch (Photo 2)<br />
Cuts/Laceration, Projectiles Wire<br />
Handleather glove, long sleeve shirt<br />
+<br />
2 1D When required, Use Wire Cu ter, Trim from Center of the Ro l Cuts, Puncture<br />
Handleather glove, long sleeve shirt<br />
+<br />
Fo low manual handling procedure properly,<br />
Muscle Strain, Cuts/Laceration, Fa l/Trip<br />
1,2 1E Ro l the Wire Ro l and Position behind the Wire Rack (Photo 1)<br />
team work, housekeeping, provide plastic/wire<br />
Hazard<br />
bin, hand leather glove +<br />
Fo low manual handling procedure properly,<br />
Muscle Strain, Cuts/Laceration, Fa l/Trip<br />
1,2 1F team work, housekeeping, provide plastic/wire<br />
Ro l the Wire Ro l into the Rack using the ramp from the rear of Wire Hazard, pinch point<br />
bin, hand leather glove +<br />
Stand, Place Shaft into Center Ro l, Pu l out 1 foot of Wire (Photo 3)<br />
When the Wire is about 2-3 feet or 1 meter left, Latch the wire together<br />
Constant communication with coating operator,<br />
1,2 by placing Fist on the Wire and Spring the Wire back, then release with Pinch Point, Cuts, Laceration, Puncture<br />
emergency stop, hand leather glove<br />
your two finger (Photo 4)<br />
Push Buzzer ONCE when Latch is made/a tached (Photo 5), to notify<br />
1 1H Non Continuous Operation<br />
Constant Communication with Plant Operator<br />
Plant Operators and others that Wires have been Latched<br />
i<br />
Watch the latched wire as i travels through the Ro lers (Photo 6, 7) and<br />
1 1I Non Continuous Operation<br />
Constant Communication with Plant Operator<br />
Applicator (Photo 8)<br />
E<br />
1,3 1J IF Latch is missed/broken/comes apart at some point of travel, Hold the Misfeed or Discontinuous Operation Never Fo low Wire into Ro ler E<br />
Buzzer Down (Photo 5) until Plant Operator STOP the Coating<br />
Repair the Latch, then Press the Buzzer to Notify Plant Operator to Start<br />
1,3 1K Misfeed or Discontinuous Operation Never Fo low Wire into Ro ler<br />
Coating again<br />
E<br />
Once Latched Wire is trave ling smoothly, Remove Shaft, Push Down<br />
Don't place your hand/finger on pinch point,<br />
1 1L Pinch Point, Cuts, Laceration, Puncture<br />
pedal to a low new Wire ro l to advance forward (Photo 9)<br />
hand leather glove<br />
+<br />
Repea the same steps until finish Concrete Coating operation. Return<br />
1,2,3,4 1M Missing Tools<br />
Housekeeping Workplace Organization<br />
a l Tools at the end of shift operation<br />
5S<br />
+ Q<br />
SOP-RJ-005<br />
WIRE FEED OPERATION<br />
END OF WIRE FEED OPERATION<br />
5S E ficiency =<br />
Forklift Driver<br />
Photo/Sketch<br />
Key Points Safety =<br />
Quality =<br />
5S =<br />
Information =<br />
E CMV =<br />
Environmental =<br />
SOP Revision #: 001 Originator: CCT Team<br />
Revision Date: 3-Feb-10<br />
Status:<br />
Approved<br />
Page: 1 of 1<br />
Protection<br />
Protection<br />
Center Shaft<br />
Photo 1 Photo 2<br />
Join Latch<br />
Photo 3 Photo 4<br />
Wire Rack
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