Mobile Fire Extinguisher Trainer MFET

Mobile Fire Extinguisher Trainer MFET

Dubai Aluminium ( DUBAL ) Vision To be one of the best companies in the global aluminium industry in production, markets, people and results by 2020. One of the world s largest producers of primary aluminium Smelter (>1,000,000 mtpa) Casthouses (>1,143,000 mtpa) 2,350 MW power station (30 C) 30 million gallon/day desalination plant Port facilities Warehouses Administration Residential area

Opportunity of Innovation Dubal trains employees for fire fighting - Scheduled: 1200 Emp./year - Actual 300 Emp./year due to work constraints Effects of Untrained Emp. Video *refer to video 1 untrained (Before) Employees spend time to attend - Approx. 144 hrs/year for training 1200 emp. considering 3hrs session for training of 25 emp. Normal Fire used - Environment effect Pollution Lots of Logistics Involving Manpower and Equipment Old Practice Video *refer to video 2 Fire Training Ground (Before) An alternative approach is required for Fire Training of our employees that is more efficient

Preliminary Research NFPA 1403: Standard on Live Fire Training Evolutions NFPA 1402: Guide to Building Fire Service Training Centers NFPA 58: Liquefied Petroleum Gas Code, 2011 Edition NFPA 70E: Handbook for Electrical Safety in the Workplace, 2012 Edition Explore the ways to adopt and benchmark with Best Practice and new technology in the field of First Aid Fire Extinguisher Training

Techniques to Generate Idea Brainstorming Procure Fire Simulators form Market Invent a customized fire simulator suitable for the plant Ideas targeting a more efficient approach that is cost-effective, time saving, environment friendly and user friendly.

Advantages and Disadvantages of Concepts No. Option Advantages Disadvantages Decision 1 Procure Fire Simulators form Market 1. Readily available on demand 2. High-Tech and Efficiency 1. Expensive 2. Extensive training required (Rejected) 3. Maintenance Cost 2 Invent a customized fire simulator suitable for the plant 1. Customized to our requirement 2. Cost effective 3. Environment friendly - 3 R Concept 1. Extra efforts required 2. Time for inventing the new simulator (Accepted) Invent a Customized Fire Simulator A CHALLENGE IN HAND

TRIZ - Contradiction If we organize fire training in the areas But (-) Then (+) Need to move the training ground to the areas Employees will get trained easily as and when required If we do not organize the training in the areas But (-) Then (+) Employees will not get trained easily as and when required No need to move the training ground to the areas Established Contradiction: Employee shall get training easily as and when required and there is no need to move the training ground to the areas Objective: Develop a training mechanism which can provide fire training to employees as and when required and no need to move the training ground

TRIZ Principles used to build ideas Improving Feature Worsening Feature Volume of moving object Principle 15 Dynamicity Principle 35 Transformation of physical and chemical states Principle 29 Use of hydraulic and pneumatic construction Adaptability or versatility 15, 35, 29 C 15: If one object is immovable, make it movable or interchangeable 29: Replace solid parts of an object by gas or liquid. These parts can use air or water for inflation or use air / hydrostatic cushions Develop a movable object that can operate through pneumatic or hydraulic construction

Team Formation A Team Consisting of the following Member was formed to gather all the Expertise and Knowledge needed to work on the project: 1. Saif Al Meskiri (Head of Loss Prevention) 2. Policarpio R T, 3. Thabet Abdel Ghani, 4. Davichan M D, 5. Edgardo Delos Santos 6. Abutariq Procurement of materials Designing/Enginee ring Drawing Liaison with Safety Execution of Job Testing / Commissioning

Stakeholders Buy-in Resistance Addressed Cultural Resistance/Fear of Unknown - Slow & planned change implementation - Demonstrated improved safety aspects, environmental impact and ease of access to employees - Cost benefit Analysis was done Adopting a new approach or practice - Conducted pilot trial before full scale implementation - 100% customization to Dubal s requirement - Recyled Materials used SNR. MANAGER CBCM, ASSETS PROTN & LOSS PREVNTION approved and sponsored the project

Design Process

Designing Plan Sr. No. Task Responsibility Target Date 1 Decide on the relevant design standard Saif, Rod, Thabet, ED, Davichan, Abu, 2 Decide on the type of parts/technology to be used 31 st Jun, 2012 Saif, Rod, Thabet 30 th Dec, 2012 3 Decide on the appropriate safety and extent of coverage 4 Assembling the Fire Mobile Extinguisher Saif, Rod, Thabet 31 st Oct, 2012 Rod, Thabet 15 th April, 2013 5 Pilot implementation Saif, Rod, Thabet 30 th April, 2013 6 Mitigation of the risk/findings Saif, Rod, Thabet 15 th May, 2013 Regular meetings to review the statuses of the project were carried out

Implementation Plan Specific responsibilities assigned to various team members

Before Rolling-out and Proving for Implementation: - Real demonstration for pilot departments was conducted Testing (Piloting) Sr No. Task Responsible Target Date 1 Testing of Mobile Fire Extinguisher Saif, Rod, Thabet 8 th April, 2013 2 Fine tuning and retesting of the Mobile Fire Extinguisher Saif, Rod, Thabet 13 th April, 2013 3 Safety approval Saif, Rod, Thabet 15 th April,2013 4 Project completion Saif, Rod, Thabet 13 th May, 2013 During testing: - Flame was not adequate, Safety lapses - Additional features were required to create realism e.g. Smoke generator, Remote control etc.

Failure Mode Effect Analysis - FMEA

Mobile Fire Extinguisher Development Inhouse Reality *refer to video 3 Mobile Simulator (After)

Results Old Practice New Practice Ease Environment No. of trainees Safety Lot of preparation required (e.g. fire fuel, torch, fire training ground etc.) Pollution due to burning of combustible and flammable material Scheduled trainees per year: 1200 employees Actual trainees per year: 300 employees (due to work constraints) Participants exposed to Heat and Toxic Gases Self-contained Built-in technology Environmental friendly fuel (Liquefied Petroleum Gas) Controllable environment Since 5 months of implementation 600 emp. Trained Expected approx. 1500 trained emp. per year Environmental friendly fuel agent No smoke emission Fire can be controlled remotely

Old Practice Time 3hrs Session 25 emp. trained Results Approx. 144 hrs /year to train 1200 emp. (Night training is not possible with old practice) New Practice 1hr session 25 emp. trained Approx. 48 hrs to train 1200 emp/year. Saving of 96 hrs / year (66% saving ) Cost Avg cost of DUBAL Employee @AED 95 /hr. For 3600 (1200emp X 3hrs/session) man hours, the cost is AED 342,000 per year (24/7 feasible) Avg cost of DUBAL Employee @AED 95 /hr. For 1200 man hours (1200emp X 1hr/session), the cost is AED 114,000 per year Approx. AED 228,000 equivalent of productive hours are available for utilization. Feedback from Customers Through face to face meeting post training, customers positive about the flexibility, time saving and quick familiarization.

Learning What Went Well? Team work and coordination has taken a big role in the success of the project. Management Support is a Key to the success of the project. Single Point Lesson: To excel in Customer Service, Be close to your customers and bring in your solutions.

Way Forward Optimization of the training target according to the organization s requirement as limitations have been reduced. Manufacturing Units according to the needs of different customers externally. The invention is awaiting for the patent rights. Mobile vehicles are now being adopted and utilized in other areas as Maintenance Area (horizontal deployment) The project was recognised by UK-based The Institute of Fire Engineers ( IFE ).

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