TR and AJ had their improvement implementation policy checked and approved by their superior, had small groups at the workshop consider it, heard their opinions, and then made the following improvements:
1. Computed and secured the necessary space for maintenance inspection of the cabinet panel. They also secured the path to the cabinet panel.
2. The shape of the storage shelves was decided according to the length, type, and make up of the steel bars.
3. The number of levels of the shelves was decided according to the methods of putting and taking out materials. For example height and a foothold had to be considered if the bards were moved by hand.
4. For work done by forklift, a method had to be considered which would prevent materials from collapsing (falling).
5. There had to be enough space secured around the shelves so that work would not be hindered.
6. Steps for putting in and taking out materials were decided.
Reorganization New System Improvement Implementation Policy for materials Storage Area
After Tripathi and Ajit clarified the current situation, they set their improvement implementation policy.
1. The electrician in charge will secure the path to the cabinet panel (how wide it should be, how will be marked), and the amount of space necessary for inspection (secure the necessary square meters of space, how it will be marked).
2. The person in charge of long materials, such as the steel bars, will decide how to reorganize the materials, make shelf divisions, and how much space will be necessary around storage shelves for taking out and putting in the materials (number of levels, depth, width, space between posts, etc)
3. These two persons in charge will consult each other and make adjustments.
4. The conditions set will be observed by all, a person in charge appointed and his responsibilities defined.
When making up concrete “reorganization” policies, it is vital to seek the opinions and ask about the experience of workers at the workshop, so that as much information based on fact be gained as possible.
Labor safety rules in Japan stipulate:
1. That, for example, there must be a space of at least 80 cm between two machines, and
2. That an aisle must be free of obstruction from the floor up to 180 cm, and
3. That if work is done at a height of over two meters, it is called elevated work, a foothold must be provided and measures taken to prevent falling of objects. There are also rules that say that if a worker has to climb more than 1.5 meters, stairs or a ladder must be provided.
Reorganization Steps after Improvements
1. Storage operations have to done by the set methods and steps (standardized operations). It is especially important for operations that have not been mechanized and are done on the judgment of workers to be done strictly according to standard.
2. When materials are taken from the top level by hand, the shelves must not be used as stepladders. A foothold must be provided.
3. Materials must not be left in the aisle or in front of the cabinet panel. If even one item is left once, the situation will return to pre-improvement conditions.
Expected Effects after Improvements:
There are four safety rules. The expected effect of “reorganization” improvements in this case is for a dangerous situation to be avoided. The situation is organized as follows:
Rule No. 1 Reorganization – Maintenance
The area for material (steel bar) storage and that in front of the cabinet panel were reorganized, and work can be done with a sense of safety, thereby avoiding a dangerous situation.
Rule No. 2 Inspection – Maintenance
The area in front of the cabinet panel and aisle leading to it were secured, so the electrician can now do inspection and Maintenance in safety.
Rule No.3 Standardize Operation
The steps for material storage operations were clarified, a basic operation rhythm established, and unsafe behavior discontinued.
Rule No.4 “Communication – Adjustment”
Through these improvement activities, effective adjustments were made with the cooperation of the electrician and the person in charge of material storage.
So, what did you learn from this example? Assuring safety means that work can be done at a steady pace, that the work shop is reorganized into such a place. When you make efforts to improve safe working conditions, first make sure that reorganizations has been done.
Refer to previous examples.