Process Flow Diagram Welcome to MIRAE INDUSTRIES Co.,LTD Global marine equipment provider

• 
• PROCESS
• Process Flow Diagram
• Process Flow Diagram

• Process Flow
  
  
• Raw material
  

  Explanation on the process

  When raw materials(steel plate, forging, pipe etc.) are ware housed, unload by classifying into each line using a forklift.

  Store unloaded raw materials after classifying them into the thing that is required for bolier making process and the other.

  Ransport stored materials to dach applicable process using a forklift when fitting-up is being implemented.

  Facilities & Equipments to be used

  Forklift

  Main dangerousness, harmfulness,
  hazardous substance

  Forklift and colosion

  Overturn or narrowness due to unsafe freight loading

  Narrowness due to discordance of hand signal method

  Non-designation of foreman when handling heavy material

  Safety & Improvement measures

  Attach a waming sign ‘speed limit s 20 km’ installation of taillight, headlight and alert sounds

  Use of proper forklift and advance inspection of weight

  Be sure to move after confirming foreman’s signal when hand signal is required

  Work with advance hand signal in respect of product that securing a clear view is unable among heavy materials(two-person team)

  Forklift-related safety education

  
• Boiler Making

  

  Explanation on the process

  Plan the shape of each cut component by fitting-up after referring to the floorr plan.

  Cut steel plate using oxygen futter after marking a portion of steel plate materials and proceed with fitting-up process

  Conduct welding process for each single product that fitting-up is completed.

  Facilities & Equipments to be used

  Co2 welder

  Oxygen cutter

  Crane

  Cutter

  Hand grinder

  Main dangerousness, harmfulness,
  hazardous substance

  Fire and explosion due to of LPG, oxygen / oxygen cutter

  Narrowness and cut when using figh-speed cutter

  Ocular diseases due to failure of wearing protective goggle in th course of selding

  Damage to eyes due to noise / iron filling dust scattering in the course of grinding

  Health disturbance due to (harmfulness) welding groove

  collision, falling, narrowness in the course of crane work

  Safety & Improvement measures

  Check hose for irregularities during the process.

  safety education

  Check sutter protecrtor for irregularties / designate the phrase ‘warmning : inspection’

  Implement training to wear welding mask and protectibe goggle at all times.

  Wearling protective goggle and earplug is recommended.

  Istall dust scattering protective partition and ventilator within the work place

  Be sure to wear a dustproof mask and implement safety education on health distrurbance.

  Implement stretching on a periodic basis(musculoskeletal system disorder)

  Understanding of surrounding working cpmdotopms / periodic ispection

  
• Machining

  

  Explanation on the process

  Work welded product by referring to the size specified on the floor plan.
  Drilling / boring / radial work are the main methods of working

  while operation is made based on the boring operation durring the primaty processing, floor plan size and tolerance processing / punching for radial work are impelmented in the secondary processing

  Upon completion of boring processing, ‘HOTE’ and ‘TAP’work are carried out on the punching location using a redial

  Conduct lathe milling process for the rest small - sized processed products.

  Facilities & Equipments to be used

  Lathe

  Tadial

  Milling machine

  Boring machine

  Crane

  Forklift

  Main dangerousness, harmfulness,
  hazardous substance

  Beting shoved by the rotating body of machine

  Backache when handling heavy material

  Narrowness due to faulty sling belt work

  Abrasion / cut due to chip dust scattering

  Health disturbance due to use of(toxic substance) cutting fluid / slide-way oil

  Colision, falling, narrowness in the course of crane work

  Safety & Improvement measures

  Pay special attention and implement inspection prior to operation of machine / use of leather gloves is recommended.
  Implement stretching on a periodic bass(musculoskeletal system desorder)

  Inspect state of tailpiece and use an exclusive clamp

  Istall chip dust scattering prevention facilly

  Wearing protective goggle and mask is recommended.
  put up safety instruction and indicator board.

  Understading of surrounding working conditions / periodc inspection

  
• Pre-painting

  

  Explanation on the process

  Conduct shot blasting for processed product for removing rest and painting

  paint product that shor clasing is completead according to the painting specifications using painting equipment in order of wash painting / sealer / top painting

  Dry painted products

  Facilities & Equipments to be used

  Painting facility

  Crane

  Short gun

  Painting machine

  Spray gun

  Main dangerousness, harmfulness,
  hazardous substance

  Risk of fire due to work using paint and thinner

  Health disturbance due to use of (jazardous substance) paint / thinner

  Collision due to use of forklift

  collision, falling, narrowness in the course of crane work

  Safety & Improvement measures

  Remove the source of ignition and DO NOT USE inflammables within the workplace

  Wear a dustproof mask, canister mask and protectibe clothing.

  Attach MSDS(Material Safety Date Sheet) indicator board and implement education Inspect local ventilation system and replace filter on a periodic basis(bi-monthly)

  Refer to the forklift safety instruction

  Understanding of surrounding working conditions / periodic inspection

  
• MW

  

  Explanation on the process

  After warehousing painted product into the plant using a forklift, review and arrange gear-case from the upper by referring to the floor plan of each line and assemble washed gear in each location in order of floor plan. After assmbling gear-case, assemble in order of drum clutch, stand, band and warping

  Facilities & Equipments to be used

  Tank for washing gear

  Sling belt

  chain vlock

  Air grinder

  Heating furnace(shrinkage fitting)

  Impect wrech

  Spanner /Hammer

  Hoist

  Main dangerousness, harmfulness,
  hazardous substance

  When used for cleaning gear oil tank fire

  (Hazardous materials). Health problems coused by the use of thinner

  Shrinkage fit caucaution when working with images

  Hand tools(hammer) caused by the use of a stenosis(finger)

  Grinding noise when working / metal powder eye damage by scattering

  Stocked for a long time due to reperirive work and nusculoskeletal

  Crane / forklift operations collision, fall or narrowing

  During welding thinner due to the use of fire

  Safety & Improvement measures

  Keep a fire ectinguisher around the tank

  Wear a dustproof mask

  Wear arm warmers and raduat gloves

  Remoce rest elements usibg a JIG

  Wearing protective goggle and earplug is recommended.

  Implement stretching ib a a periodic basis.(musculoskeletal system disorder)

  Understanding of surrounding working conditions / periodic inspection / forklift safety

  Implement education and point out mutually to prohibit inflammables in the course of welding process.

  
• WL

  

  Explanation on the process

  After warehousing painted product into the plant using a forklift, arrange from the frame location by referring to the floor plan of each line and proceed in order of dricing shaft, calble lift and band lever handle as specfied in the floor plan

  Facilities & Equipments to be used

  Hammer

  impact wrench

  sling belt

  Spanner

  Chain block

  Hoist

  Air grinder

  Main dangerousness, harmfulness,
  hazardous substance

  Health disturbance due to use of(hazardous substance) thinner

  Stenosis(finger) due to use of hand tool(hammer)

  Damage to eues due to noise / iron filling dust scattering in the course of grinding

  Musculoskeletal system disorder due to stading and repetitive work for long hours

  Safety & Improvement measures

  Wear a dustproof mask

  Remove risk elements using a JIG

  Wearing protective goggle and earplug is recoomended.

  Implement stretching on a periodic basis. (musculoskeletal system disorder)

  Understading of surrounding working conditions / periodic inspection / forklift safety

  Implement education and point out mutually to prohibit imflammables in the course of welding process.

  
• TEST

  

  Explanation on the process

  After self-test by conductiong a performance test on the assembled winch at the shop testing ground, implement owner inspecion and classification survey. tests shall be implemented in accordance with test procedure as follows

  Facilities & Equipments to be used

  Shop test facility

  Hoist

  impact wrench

  Jig for testing

  Sling belt

  Main dangerousness, harmfulness,
  hazardous substance

  Sliding tue to oil leakage on the floor of workplace

  Accident due to discordance between worker and signaler

  Damage due to damated wire in the couse of testing pricess

  Dermatitis due to use of(toxic substance)gear oil / hydraulic fluid

  Collision, falling, narrowness in the course of crane work

  Safety & Improvement measures

  Remove oil using thinner / fabric right after completion of work

  Be sure to moce after confirming foreman’s signal when hand signal is required.

  Maintain safety dispance using wure and attach a safety sign in the course of testing process

  Wearing rubber gloves is recommnended when sashing and oil work

  Understanding of surrounding working coudtions / periodic inspection

  
• Post Paint

  

  Explanation on the process

  Upon completion of product inspecion, implement sanding process for failed painting and danaged part using a sanding machine and wash

  oil on the product and conduct top painting*final) using painting equipment

  Dry painted products

  Facilities & Equipments to be used

  Painting facility

  Crane

  Spray gun

  Painting machine

  Main dangerousness, harmfulness,
  hazardous substance

  Risk of fire due to work using paint and thinner

  Health disturbance due to use of (hazardous substance) paint / thinner

  Dollision due to use of forklift

  Collision, falling, narrowness in the course or crane work

  Safety & Improvement measures

  Remove the source of ignition and DO NOT USE inflammables within the work place.

  Wear a dustproof mask, canister mask and protective clothing, and attech MSDS(Material Safety Date Seet)

  indicator board and implement education.

  Inspect local ventillation system and implement education

  Inspect local ventilation system and replace filter on a periodic basis(bi-monthly)

  Refer to the forklift safety instruction

  Understanding of surrounding working conditions / periodic inspection

  
• Release

  

  Explanation on the process

  Hang up completed m / winch and winlass on the crane and load on the vehicle using sling belt and chackle

  Load up completed product on the pallet on the vehhicle using a forklift and release by fixing product witha belt

  Facilities & Equipments to be used

  Forklift

  Crane(Hoist)

  Shackle / Sling belt

  Main dangerousness, harmfulness,
  hazardous substance

  Overturn when lifting optimal weight for forklift

  Collsion, falling, narrowness in the course of crane work

  Overturn of product due to use of abnormal sling belt

  Narrowness due to discordance of hand signal method

  Safety & Improvement measures

  Use of proper forklift and adbance inspecion of weight

  understanding of surrounding working conditions / periodinc inspection

  Inspection state of tailpiece and use an exclusive clamp.

  Work with advance hand signal in respect of product that securing a clear view is unable among heavy materials.(two- person team)

  Forklict-related safety education