Case Study TasRail - Vehicle Hoist

 

Situation / Driver:

  • The project commenced in 2016 to engage with employees to capture and demonstrate the business case to procure a new vehicle hoist for installation at East Tamar Junction
  • There was significant potential for injury due to the position Maintainers needed to get in to maintain the equipment
  • There was a risk that areas of the Checklist within Smart Asset could not be complied with due to the inability of the guys to get under the vehicle.  This meant that maintenance was not undertaken as effectively and efficiently as it could be in the hard to get to places
  • The TasRail inspection schedule was not systematic due to changes in roles
  • The Checklists need to be reviewed to ensure that they are efficient, effective and complied with

Impact this was having:

  • The maintenance tasks are currently very manual and because wheel weights are up to 26kg this means that there is a risk to employees of manual handling injuries.  Take 5’s and risk controls are in place to control the risks as much as is practicable

The Approach undertaken:

  • Under the guidance of an External Facilitator, Mal Bygraves used the Plan-Do-Check-Act methodology to:
    - Understand the current situation, the issues and causes of the issues
    - Frame up possible solutions
    - Implement the solutions
    - Understand the difference these solutions made
    - Standardise for the future

Solutions implemented:

  • A review of outsourcing versus in-sourcing was undertaken in consultation with management and employees
  • Expression of Interest prepared and sent out with 2 companies responding
  • Costing gathered and a business case developed
  • Checklists were reviewed and procedure INF-TS-611 updated
  • Change management for the procedure above was undertaken to introduce enhanced work practices
  • Lean 5S introduced with the team to improve their work layout, housekeeping and organisation

Benef its Achieved:

  • Decreased risk of manual handling injury
  • Improving employee morale
  • Improving engagement of employees
  • Improved housekeeping and reduced hazards due too Lean 5S being progressively implemented
  • Improvement of:
    - Condition monitoring of vehicle body chassis inspection
    - Hi-Rail sub-frame inspection and repairs
    - Rear buffer stop repairs
    - Manual handling of Hi-Rail repairs – front and rear
    - Compressor and hydraulic repairs

Future Plans and further work required:

  • Greasing/Lubricating of Hy-rail components previously unreachable
  • Reduced Manual Handling/Ergonomic job tasks
  • More thorough Condition Monitoring /reporting of underframe components
  • Increased  inspection regime of vehicle fleet as they age
  • Continuous improvement through Lean 5S