Process System Block
A pictorial model of a process or system is defined as a block diagram. These block or box diagrams, to a great extent are used in the engineering world like hardware design, software design and process flow diagrams. The block diagrams are distinctively used for a higher level and less detailed description, which aim more at understanding the overall concepts and less at understanding the details of implementation. On contrary, the conventional diagram and layout diagram are used in the electrical engineering world.
The conventional chart shows the details of all electrical components whereas the layout diagram shows the details of physical structure. For instance, a block diagram of a radio is not expected to show each and every wire, dial and switch, but the schematic diagram shows the details. The drawback of conventional diagram is that it does not show the width of each wire in the printed circuit board, but the layout diagram shows these wires.
In designing new processes and for improving existing processes, a block diagram is a useful tool. In both the cases, the block diagrams provide a quick and high-level view of the work and rapidly lead to process points of interest (Block Diagram, 2008). It may not offer the level of detail required for more comprehensive planning or analysis because of its high-level perspective. Thus, it is important that all the team members who create a block diagram must have a clear understanding of how the process functions (Block Diagram, 2008).
Block Diagram is used to institute the boundaries of a system under the given conditions. It outlines the element contained within the scope of a task and also helps in developing P-diagram, Flow Chart, FMEA and other documents. It identifies inputs and outputs for components within a system. It describes the relationships between systems/components, recognizes redundancies in systems and establishes critical paths through systems (Block Diagram: Overview, 2008).
Widget
Widgets are small html fragments in an iframe, which an individual can install on their web server. An iframe is like a mini web browser, inside of a web page. Our widget integrates all the functionality of a job board (Lozinski, 2008). A widget is a meta-thing used to stand for a real object in didactic examples. Widget is an element of a graphical user interface that displays information or provides a specific way for a user to interact with the operating system and application (Lozinski, 2008). It allows the user to interface with the application and operating system. It comprises of pull-down cards, buttons, selection boxes, progress indicators, on-off checkmarks, scroll bars, windows, window edges, toggle buttons, forms, and many other devices for displaying information and for inviting, accepting, and responding to the actions.
Analysis
The given block diagram, explains the production process and hazards involved in each step. In this diagram, the widget enters into the production process. There are various hazards that the operators have to identify and manage in the production process. Operators in the production process have to always face the problem of bringing non-hydrocarbons contaminants to the surface during production (Analysis, 2001). In general, these contaminants have various things common. Before putting them in the market, these non-hydrocarbons contaminants must be removed from the hydrocarbons. These contaminations are typically found in the well effluent prior to processing (Analysis, 2001). It also includes hydrogen sulphide and water, which are regularly removed from the hydrocarbons phase on both fixed and floating installations.
The problem that was faced during the flow of production was improper gas flow, dirty lenses, improper settings, etc (Gillespie, 1988). The variations in the work piece were also affecting the laser cutting. There was the cutting performance deterioration which caused the nozzle interference, improper focal point location and improper gas flow (Gillespie, 1988). There was a problem of interlock light, due to which the system was overheated and the supply was exhausted (Gillespie, 1988).
The practice was not running properly, which was possibly causing trash data problem.
CRT and CNC were not operating properly due to which there was a problem and loss of executive tape (Gillespie, 1988). The problem of high and low voltage was also there, which was causing switching of gas even in the standby mode (Gillespie, 1988). The water supply also used to get off. Due to high voltage the depression was not for long time. The machining was very slow; due to which there was a high tool mass.
Problem in welding blench
A materials joining process used in making welds is defined as welding. The welding and cutting operations present in certain potential hazards to welders result in temporary or permanent physical injury, short or long-term adverse health effects, discomfort and even death (Labour, 2007). The prospective health hazards connected with welding and associated processes comprise of exposure to heat, smokes and gases, noise, radiation as well as muscles and skeleton injuries (MSI's) like strains and sprains.
Smoke produced during welding is comprised of solid particles, usually less than 1.0 μm in size. They are formed by condensation and oxidation of the vaporized metal. In the gas-exchange region of the lungs, these particles are capable of being deposited (Labour, 2007). The composition of the chemicals of the welding fumes and gases not only depends on the welded material but also on the procedure and the conductors used (Labour, 2007). The possible health hazards from exposure to welding fumes are not only dependent on the welded metal, the process and the physical composition of the welding conductor, but also on the work environment, including the location (indoor vs. outdoor), the type and quality of natural and mechanical exhaust ventilation, degree of enclosure of the work station, length of exposure, and personal protection equipment (Labour, 2007).
Another problem in the welding bench that was recommended by the workers was that there is an occasional smell in that particular area. They compliant the smell is of truck exhaust. According to them, there is haze over the welding bench due to which there was frequent headaches, dizziness, etc.
The most common types of welding processes used in the production process are:
- shielded metal arc welding (SMAW)
- gas metal arc welding (GMAW) (Labour, 2007)
- flux-cored arc welding (FCAW)
- gas tungsten arc welding (GTAW)
- plasma arc cutting (PAC) (Labour, 2007).
- air carbon arc gouging
- metal-cored arc welding (MCAW)
Chemicals used in production process
The chemicals that are used in the production process are adhesives; anticreasing agents; antifoaming agents, antishrinking agents, antislip agents, antistats, (Research and Markets: Handbook of Textile Processing Chemicals, 2004), binders, biocides, bleaching agents, antioxidants, carriers, chelating agents, flame retardants, Foaming aids, fulling agents, leveling agents, Lubricants, Mercerizing assistants, (Research and Markets: Handbook of Textile Processing Chemicals, 2004) Oil repellants, Oxidizing agents, coning oils, preservatives, reducing agents, scouring agents, sizing agents, softeners, soil repellents, solvents; stripping agents, thickeners, water repellents, wetting agents and whitening agents (Research and Markets: Handbook of Textile Processing Chemicals, 2004).
Fumes and their Health Symptom:
The most common metal fumes and gases that may be generated during different types of welding and thermal cutting are:
|
No. |
Smokes |
Effects and Symptom |
|
1. |
Cadmium oxide |
Nose irritation and ulceration; Pulmonary edema, chronic effects comprise of kidney damage and emphysema, prostate, lung cancer, pulmonary fibrosis ( Labour, 2007) |
|
2. |
Chromium (VI) |
respiratory tract irritation, effects on nose, eyes and ears; Skin irritation, chronic effects ( Labour, 2007) |
|
3. |
Nickel |
Dermatitis, asthma-like lung disease; chronic effects include cancer of nose, larynx, lung, renal dysfunction |
|
4. |
Fluorides |
Eye, nose and throat irritation, gastro-intestinal symptoms; chronic effects include bone and joint problems, fluid in the lungs, kidney dysfunction |
|
5. |
Nitrogen oxide |
nausea, dizziness, Headache, collapse, death, cardiovascular effects ( Labour, 2007) |
Material Safety Data Sheet (MSDS)
With respect to welding bench, while looking into the prospective health hazards, it is important to consider the material safety data sheet (MSDS) for each controlled product that is used in the welding operation (Labour, 2007). This MS data sheet defines the health hazards related with the use of these products. The role of these documents is to provide recommendations regarding preventive measures like engineering controls and personal protective equipment (PPE) (Labour, 2007).
Threshold Limit Values
In addition to the material safety data sheets, the CSA Standard W117.2 and other documents that might be helpful in the investigation of health hazards should be referred (Labour, 2007). It is essential that the following documents are consulted:
- The American Conference of Governmental Industrial Hygienist ACGIH:
- The ACGIH Documentation of the TLV should be developed as a guideline to assist in the control of health hazards (Labour, 2007).
Application of health and Safety legislation
The occupational Health and Safety Act 2000 (OHS Act) aims to protect the health, safety and welfare of people at work. This act was replaced with the 1983 Act. OHS is the integrated safety solution consultancy that really understands the complex world of HSE legislation (Summary of the OHS Act 2000, 2008) It contains new provisions which command that every employer should consult with their employees regarding health, safety and welfare matters. This act includes both the employees and the employer. According to this, employers have a responsibility to provide a safe system of work to their employees and their employees have a duty to follow whatever directions they are given by the employer (Summary of the OHS Act 2000, 2008). If there is difference of opinion between the provisions of the related legislation and the provisions of the OHS Act, the provisions of the OHS Act should be adopted.
According to the section 8(1) of the Occupational Health and Safety Act, an employer should ensure the health, safety and welfare of all the employees. The responsibilities of employer or manager under the OHS Act are:
Safe location
Provide safe machinery to use
Safe work environment (Summary of the OHS Act 2000, 2008)
Provision of training and supervision
Providing suitable working atmosphere and facilities
The Act also states that you are responsible for the health and safety of the people other than your workers, who may be present at the workplace. The employers should provide a safe working condition ensuring safe entrances and exits (Summary of the OHS Act 2000, 2008). The prime job of manager is to ensure the safe use, handling, storage and transport of plant and substances (Summary of the OHS Act 2000, 2008)
Objectives of Occupational Health and Safety Act
The objectives of the Occupational Health and Safety Act are to:
Promote security and health keeping the safety and welfare of the people in the mind
Protect people against the risks of health and safety in workplace (Occupational Health and Safety Act 2000, 2003)
in achieving the objects, the emphasis should be on consultation and cooperation between employers and workers
Ascertain that risks are identified, evaluated and assessed.
build up and encourage awareness of occupational health and safety issues among the employees (Occupational Health and Safety Act 2000, (2003)
provide a legislative framework that allows for progressively higher standards of occupational health and safety in work practices
Protect people against risks arising from the use of machinery, equipment, etc (Occupational Health and Safety Act 2000, 2003)
Recommendations
To avoid the problem of welding bench, it is recommended that while cutting performance deterioration, the nozzle tip should be realigned and the direction of focal points should be checked (Gillespie, 1988). The improper flow of gas can be checked by proper flow of meters. It is also suggested that the dirty lenses should be timely removed and replaced to avoid delays. The interlock light problem can be solved by installing new gas bottle. It is suggested that front doors should be closed. On gas housing, the knob should be pulled. The shutter should be switched to open. The practices should be done to reload the pattern in different locations. For operating CRT or CNC correctly, the executive tape should be reloaded timely (Gillespie, 1988).
To move the tables in block diagram, it is suggested that the power switch should be turned on. To set the feed rate at zero, it is recommended that the present feed rate should be reset (Gillespie, 1988). It is also suggested that to avoid the voltage problem, the gas switch should be opened in standby mode. The water supply should be turned on. The voltage should be depressed for a minimum of 5 seconds (Gillespie, 1988).
The slow machining can be maintained by reducing the tool mass, by changing tool design, by utilizing the grit size to vibration amplitude and by changing the slurry concentration. The improper storage problem can be reduced by avoiding the chipping and scratching in handling and storage (Labour, 2007). The health problem like the headache, irritability, sweating, dizziness, nausea, etc. can be minimized by using the fewer amounts of fumes like fluorides, oxide, nitrogen oxide, carbon monoxide, manganese, magnesium oxide, etc (Labour, 2007).
To avoid the sweet smell of welding blench, the operators should properly manage the production flow so that there is no excess passing of material. It is recommended that timely replacement and maintenance should be done to minimize the haze and fog from the welding machine. According to OHS Act, the employers should take reasonable care for the health and safety of their co-workers who may be affected by the harmful chemicals used in the production process (Occupational health and safety, 2003). It is the duty of manager to look that the employees are wearing and using the prescribed safety equipment. They are carrying out work in a safe manner and are following the instruction related to the health and safety (Occupational health and safety, 2003).
Conclusion
Thus, it can be concluded that to avoid the problems in the welding blench, the hard chemicals like antifoaming agents, antishrinking agents, antislip agents, antistats, etc should not be used by the project manager in the production process. The manager should try that the production process is easy so that the employees can easily handle it. The timely replacement should be done by the manager to avoid the delays and the fogs in front of the welding blench. In order to avoid the delays and health hazards, the employees should be trained so that they know how to use the machines and equipments. The employees should be given proper care so that they work hard and the productivity increases. It they are given proper care and benefits, they would work hard and the company would be able to achieve their targets.
References
Analysis, (2008). Retrieved June 18, 2008 from http://www.petroleumeconomist.com/default.asp?page=14&PubID=46&ISS=8621&SID=325506
Block Diagram, (2008). Retrieved June 18, 2008 from http://web2.concordia.ca/Quality/tools/3blockdiagram.pdf
Block Diagram: Overview, (2008). Retrieved June 18, 2008 from http://thequalityportal.com/q_block.htm
Gillespie, L.K. ( 1988). Troubleshooting Manufacturing Processes: Adapted from the Tool. Published by SME Manufacturing Processes.
Labour, (2007). Retrieved June 18, 2008 from http://www.hrsdc.gc.ca/en/labour/publications/health_safety/pdf/hhhcmrwap.pdf
Lozinski, C. (2008). Grab our Pharmaceutical Manufacturing and Process Validation Job Market Widget. Retrieved June 18, 2008 from http://pharmaceutical-manufacturing.specialtyjobmarkets.com/Resumes/From/SpecialtyJobMarkets/Widgets/PagesBig/GrabOurWidgets
Occupational Health and Safety Act 2000, (2003). Retrieved June 18, 2008 from http://www.workcover.nsw.gov.au/LawAndPolicy/Acts/ohsact.htm
Occupational health and safety, (2003). Retrieved June 18, 2008 from http://www.workcover.nsw.gov.au/OHS/default.htm
Research and Markets: Handbook of Textile Processing Chemicals, (2004). Retrieved June 18, 2008 from http://www.allbusiness.com/manufacturing/textile-manufacturing-textile/5204824-1.html
Summary of the OHS Act 2000, (2008). Retrieved June 18, 2008 from http://www.workcover.nsw.gov.au/NR/rdonlyres/9C6778F2-852E-4C66-BCAF-67BBB962AE01/0/act_summary_ohs_2000_1001.pdf
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