Manufacturers’ Monthly Endeavour Awards Finalists – Safety Scheme of the Year

As nominations close for the 10th Endeavour Awards, we highlight the finalists for each category, giving you an insight into innovation and excellence in the manufacturing industry.

In this feature we give an insight into the finalists for the Safety Scheme of the Year award

CONFOIL

Return To Work program

Confoil has been nominated for the Safety Scheme of the Year award for its consultative return to work program.

Since 1966 Confoil has grown into a successful Australian manufacturing business. Established as a family owned company, Confoil is the Australian manufacturer of quality aluminium foil trays and Dualpak oven able paperboard trays, also known for catering foil, film wrapping, and the Italian-made Novacart decorated paper-baking moulds.

In 2009 Confoil started to implement a new holistic, consultative Return to Work Program, involving a dedicated RTW Coordinator (who is also an accredited Workplace Assessor).

Recognising the high number of mature aged workers (in 2012 one employee received their 35 year Service Award) Confoil decided to include personal injuries as well as work-related injuries in its policy, demonstrating the company's commitment to its employees' total welfare. 

Confoil's RTW program involves the supervisor, employee, doctor, physio etc and the RTW Coordinator working as a team with the common goal to deliver suitable and ongoing medical and personal support to an injured worker to provide an effective return to work program. 

The caring of the employee's welfare starts immediately, even for minor injuries by the way of the supervisor taking the injured worker directly to the doctor.

Confoil has a partnership with local medical practitioners and occupational physiotherapists who have a strong knowledge and understanding of the work environment, allowing them to work with all parties to help develop suitable RTW goals.

Confoil visits the physio or doctor, with the employee's permission, to discuss the welfare of their employee. 

What is unique to Confoil compared to other industries is that Confoil's website has a return to work video demonstrating the different type of tasks performed for all medical practitioners to view at their desk including an injured workers own doctor.

Lost time injury frequency rate is dropping sharply as a result of the program.
 

DIAGEO AUSTRALIA

Line 4 Safety Upgrade

For increasing machine safety on its bottling lines, Diageo Australia has been nomianted for the Safety Scheme of the Year award.

Diageo is a leading beverage business with a collection of alcohol brands including Johnnie Walker, J&B, Bailey's, Guinness and Smirnoff. It operates plants at Huntingwood and Bundaberg in Australia.

A routine risk assessment identified that a number of the bottling lines at the Huntingwood plant required upgrading from a machine safety perspective.

Diageo undertook a safety upgrade project for two of its bottling lines with a view to creating a global best practice blueprint which could not only be rolled out throughout in Australia and globally.

The assessment identified the safe control system to monitor the safety aspects of the bottling line was required to satisfy Category 4 of (AS 4024.1-2006, Australia's safety of machinery standard).

A set of safety concepts were developed to share with the various stakeholders from operators, engineers through to the maintainers and managers to ensure various personnel had sufficient input.

Diageo selected a state-of-the-art distributed programmable safety control system which contained almost 800 safe I/O spread across 13 remote processing head modules distributed across the plant. It operates 130-plus discrete safety processes.

The system was then designed and implemented by a third party safety contractor (Brolton Engineering Group) to Diageo's standards.  

The project took 12 months to commission/validate. 

Diageo's Huntingwood bottling lines facility saw a dramatic improvement on the old system, a mish-mash of different safety technology that provided for no consistent safety methodology relating to the operation of the plant.

Once installed, the new system achieved improvements in safety for the bottling process, locking of guards in dangerous areas, simpler diagnostics and troubleshooting regarding safety breaches, enforcement of standard operating procedures, and an active demonstration of a commitment to safety on the plant floor.

It has been used as a blueprint for all future safety upgrade projects not only in Australia but also globally where the Diageo plant in Ireland has followed a similar project process & design
 

KONECRANES

Ertech Wangara maintenance facility

Konecranes is a global group of lifting businesses, serving a broad range of customers, including manufacturing and process industries, shipyards, ports and terminals, with more than 50 years experience in heavy lifting, overhead crane and hoist technologies.

It has been nominated for the Safety Scheme of the Year award for ensuring safer lifting within a factory.
New overhead cranes are being deployed by civil contractor Ertech in their recently completed equipment maintenance facility to service about 170 items of major plant, including scrapers, excavators, loaders and bulldozers.
A 5-tonne and 10-tonne crane have been installed at Ertech's headquarters in Wangara, Western Australia. Konecranes Australia-New Zealand business recently received the Group's top global safety award for outstanding performance among Group operations spanning nearly 50 countries and more than 12,000 employees, all of whom are trained to operate in accordance with the Group's global safety signature, "Hooked on Safety". 

Radio remotes mean safety for operators, who can stand well away from the loads being lifted and shifted. The remotes also give freedom of movement, ensuring the operators can choose a position where they have the best view of the cranes and loads

A major benefit of the new cranes is the trolley travel inverter, a separate control that delivers smooth starts, acceleration and deceleration of the load, minimising load swing and enabling fast and accurate load positioning.

Dynafamily inverter controls and pole changing controls are standard options for crane and trolley travelling on Konecranes overhead cranes.

The cranes have excellent hook approaches at both ends of the crane. The headroom requirement is minimal, which is useful in applications where there are space constraints. 

Ertech signed a maintenance agreement with Konecranes because, although they service their own construction plant, cranes are not their core business.

Regular maintenance and crane inspections will ensure that all cranes are operating to the highest levels of quality and efficiency, which will reduce workplace accidents caused by malfunctioning or defective cranes.
 

KONECRANES

Abbot Point Bulk Coal Terminal One

For its safer lifting developments that are more resistant to wear and hazardous environments, Konecranes has been nominated for the Safety Scheme of the Year award.

Konecranes is meeting the challenges of a salt air environment and a hard-working mature crane stock in fulfilling a maintenance agreement for cranes employed by Xstrata at Abbot Point Bulk Coal Terminal One near Bowen in Queensland.

The work provided by Konecranes includes quarterly inspections, remedial work and certifications on 27 overhead cranes of a number of makes and types at the terminal.

The terminal is operated by Abbot Point BulkCoal, a subsidiary of Xstrata. Terminal One was recently expanded to a capacity of 50 million tonnes a year.
The cranes being serviced at Abbot Point include shiploaders, transfer conveyors and other bulk handling equipment employed on loading coal produced by Xstrata, which is one of the world's largest mining and metals companies, operating in more than 20 countries. 

A challenge is provided by the salty air in the environment, which can corrode machinery. 
The work provided by Konecranes includes quarterly inspections, remedial work and certifications on 27 overhead cranes of a number of makes and types at the terminal. The terminal is operated by Abbot Point BulkCoal, a subsidiary of Xstrata. Terminal One was recently expanded to a capacity of 50 million tonnes a year.
The cranes being serviced at Abbot Point include shiploaders, transfer conveyors and other bulk handling equipment employed on loading coal produced by Xstrata, which is one of the world's largest mining and metals companies, operating in more than 20 countries. 
 

WILSON TRANSFORMER COMPANY

Glen Waverley factory upgrade

Wilson Transformer Company (WTC) is the leading Australian manufacturer of power and distribution transformers for the Electricity Industry. It specialises in the management and service of transformers from the first stages of design right through the transformers' life.

WTC produces a comprehensive range of power and distribution transformers to standard designs as well as custom designs. 

The company owns and operates one of Australia's largest and most capable Extra High Voltage testing facilities which can test AC voltages of up to 500 kV and Impulse voltages up to 1,600 kV. 

As a result safety is a major priority and was a key factor in the recent upgrade of its Glen Waverley factory.  

The upgrade has transformed the plant into a state of the art facility with vastly improved capacity and strengthened safety and quality processes to protect the personnel and equipment.

The design for the new testing laboratory features a unique safety control system comprising the following: Mobile Modular safety locked fencing used to zone the large test laboratory so that testing of multiple transformers is possible simultaneously; Interlocks on all access points to test laboratory high voltage substations and motor generators – to prevent access during high voltage testing; Emergency stop buttons strategically located throughout the facility used to shut down test; and the system has a dual controller that can be monitored and operated from either the large power or medium power test control room.

The new safety control system for WTC's Extra High Voltage testing facility dramatically improved all safety aspects when compared to the old system which had no safety interlocks in place.  In addition to the dramatically improved safety, the new test facility has much improved capability and throughput.