A number of regular maintenance tasks at Rugby Cement Plant exposed operatives to the risk of manual handling and finger trapping injuries. Employees involved with these tasks have designed innovative tools to minimise these risks.
The installation of kiln roller bearings requires the bearing shells to be lifted onto the kiln roller and the clearances checked. The checking may need to be repeated many times. Previously, 4 operatives were required to lift the bearing on and off the roller. A new lifting rig enables a crane to be used, minimising the risks associated with the task. The rig was used successfully during the installation of 2 kiln rollers with bearings that weighed up to 100kg.
The raw mill Sepol separator often requires the bottom bearing to be changed, this can only be done in-situ which required working in a confined space. The bearing is awkward to handle, greasy and requires fitting at head height with consequent handling and trapping risks. A simple lifting tool has been designed that enables operatives to maintain a better lifting technique, improves grip and keeps fingers and hands away from trap and nip points.
- Manual handling and trapping risks significantly reduced
- Tasks are easier and more efficiently completed
- Fewer operatives required to complete tasks
- Employee lead solution supported by management.