Before After Location: Pump Slab Area Description: Product pump/valve/pipeline color faded Description: Repaint product pump/valve/pipeline Benefit: Eliminates corroded and can extend the life of pump/valve/pipeline ZONE 2 & 4-Cost saving
Before After Location: Guard House Description: Improper storage box for driver card and personal items Description: Proper slot drawer organizer for driver card and personal items Benefit: Better space arrangement inside the guard house-Eliminates searching waste Guard house-Security
Before After Location: Jetty Description: Faded railing at the jetty area Description: Repaint the railing at the jetty area Benefit: Eliminates corroded and can extend the life –Cost Saving ZONE 2-Cost saving
Before After Location: Main Office Description: Office equipment's Description: Provide dedicate yellow line for all equipment inside main office Benefit: Dedicated place for the equipment ZONE 1-Safety
Before After Location: Jetty Platform Description: Jetty platform without signage Description: Jetty platform with signage “life jacket area” Benefit: Safety reminder to the worker that performing work at jetty area ZONE 2-Safety
Before After Location: Inside Terminal Area Description: Area without direction sign board Description: Provide direction sign board Benefit: Provide direction/information to the visitor inside terminal area All ZONES-Morale
Before After Location: OSRE Cabin Description: Corroded floor inside OSRE cabin Description: Repaint corroded floor inside OSRE cabin Benefit: Avoid corrosion becomes worst and extend the life of cabin ZONE 3-Cost saving
Before After Location: Document Store Description: Scattered box inside document store Description: Rearrange all the document box Benefit: Avoid physical hazard such as slip ,trip and fall ZONE 3-Safety
Before After Location: Paint Store Description: Found paint store not in a clean and tidy situation Description: Rearrange all the paint can on the rack provided Benefit: Make it easier for workers counting stock and find the paint color to use ZONE 3-Quality
Before After Location: Product retention cabinet Description: Found sampling tin not in order according to the label on the rack Description: Rearrange all the sample from January until present Benefit: Avoid inconvenience if a sample needed for research in case of product quality issues ZONE 3-Quality
ZONE 1-Quality Before After Location: Tool Box Talk Meeting Area Issue: Planning to built designated place for toolbox talk meeting Improvement: Improve attendance tracking by visual management Benefit: Easy tracking daily attendance (reduce 15-20 minutes waiting time)
ZONE 1- Safety Before After Location: Terminal Main Entrance Gate Issue: Found no signage in front of main gate entrance Improvement: Put the main entrance signage for an additional visitor information Benefit: Eliminate potential near miss incident (Maintain zero loss time injury (LTI))
ZONE 1-Safety Before After Location: Staff Office (Safety Helmet Storage Area) Issue: Suggest to create a designated area for staff safety helmet placing. Improvement: Easier to tracing staff inside the main office or at site Benefit: Benefit: Easy to monitoring expiry date on the safety helmet & staff tracking (Reduce searching time 5-10 minutes) By Name & Expiry date
ZONE 1-Morale Before After Location: Conference Room (Licenses & Permits Monitoring Board) Issue:Suggest to fabricate the soft board for certificate according to its month & medals housing . Improvement: To centralize the location for both important items & arrange according to expiry months (Monitor Benefit: Easier to trigger expiry date for permit & licenses . (On-time renewal)
ZONE 2-Cost saving Before After Location: Jetty Platform Issue:: Found rough friction during hose connection activity Improvement: Provide a new ramp to connect land and jetty platform to avoid rough friction during hose connection activity Benefit: Preventing marine hose from damage (Reduce maintenance cost)
ZONE 2-Safety Before After Location: Jetty Platform Issue:: Stepping on slippery floor Improvement: Provide labelling to avoid stepping on the hose ramp & attached anti-slip sticker Benefit: Avoid from slip, trip and fall (Maintain zero loss time injury (LTI)) Wording : Hose ramp, Caution ! Slippery
ZONE 2-Morale Before After Location: Garden Issue: Gardening tools are not arranged properly, unaware of missing tools Improvement: Reorganize tools according to size /type, with outline and label Benefit: Easier for tool searching and housekeeping activity (Eliminate searching time 20-30 minutes)
ZONE 3-Safety Before After Location: Warehouse Issue: Standby hose place at improper place causing obstruction to forklift movement Improvement: Relocate standby hose to marine hose rack (at jetty) Benefit: Easy access/movement of forklift in the warehouse (Eliminate property damage incident)
ZONE 4-Safety Before After – Monthly Location: Northern Tank Farm Issue: Appearance issue (long grass) & leads to biological hazards Improvement: maintaining the level of grass and repaint all faded pipeline and staircase around north tank farm Benefit: Avoid presence of biological hazard and any corroded surface on pipeline and others (Maintain zero loss time injury (LTI))
ZONE 2,3,4 & 5
ZONE 6- Occupational Health Before After Location: TTLR 6 & 7 Issue: Improper tank truck parking position causing driver difficulty to connect loading arm Improvement: Demarcation line to guide truck entering loading bay Benefit: Improved truck positioning in the loading bay and eliminate ergonomic issue (Maintain zero spill) BAY 6 BAY 7 New demarcation line BAY 6 BAY 7
ZONE 6-Cost saving Before After Location: Loading Bay 4 Issue: Difficult to connect loading arm Improvement: Indicate “Top” and “Bottom” before bay entrance Benefit: Easier to align for connected of bottom and top loading arm without stretch and bend (Reduce maintenance cost ) Top Bottom
ZONE 1-Productivity Before After Location: New DT & Seal room Issue: DT&Seal boxes on the floor, blocking each other arrangement DT not in sequence Improvement: Arrange DT&Seal according to the FIFO. Benefit: (Eliminate searching time 20-30 minutes)
ZONE 2-Productivity Before After Location: Jetty Issue: High discharge time (hrs) for ADO product due to small hose size Improvement: Upgrade ADO jetty manifold from 6 inch to 8 inch size Benefit: Increase discharge rate from 32 hrs to 24 hrs , reduce potential demurrage , cost saving 30K USD/month NIL
ZONE 1-Safety Before After Location: Guard House & Main Office Issue: Unsafe location for driver registration point during truck ingress terminal Improvement: Relocate to “One stop point” for driver registration Benefit: Avoid drivers from expose to hazard, Reduce driver movement (steps) from 100 steps to 50 steps
One Stop Point for Driver BLT main office Dispatcher room Driver’s standing area At guard house Truck parking area Truck ingress area Guard house Dispatcher room 1 2 3 4 BLT main office Dispatcher room Driver’s standing area At guard house Truck parking area Truck ingress area Guard house Dispatcher room 1 2 3 BEFORE AFTER 1. Driver has to go to 2 different places (guard house and dispatcher room) = 100 steps 2. Drivers are exposed to hazards from truck coming into the terminal 1. Driver only go to 1 place Since security guard is sitting in the dispatcher room = 50 steps (reduce 50%)
ZONE 1-Safety Before After Location: OSRE Cabin Issue: Unorganized OSRE equipment in OSRE cabin, potential to searching waste during emergency Improvement: Reorganize OSRE equipment according to Last In First Out (LIFO) Benefit: Eliminate searching loss, improve emergency response time
ZONE 1-Safety Before After Location: Fire fighting shed Issue: Fire fighting suit and boots not organized Improvement: Organized fire fighting suit and boots according to size Benefit: Eliminate searching waste, improve emergency response time 5 minutes to 2 minutes
Before After Location: Testing Room Description: Gloomy and dull working environment Description: Wall painting, hang critical signages & guidelines Benefit: Boost up employee morale, creating better working environment ZONE : 1
Before After Location: Testing Room Description: Gloomy and dull working environment Description: Wall painting, hang critical signages & guidelines Benefit:Boost up employee morale, creating better working environment ZONE :
Before After Location: Buffer zone next to KTM railway (near to jetty) Description: Tall bushes inducing biological hazards Description: Removing Benefit: Providing safer working environment to the employees ZONE : 2
Before After Location: Description: Marine hose exposed to sun and rain- may reduce the hose lifetime Description: Fabricated a roof to keep marine hose covered from sun and rain Benefit: Increase the marine hose lifetime ZONE : 2
Before After Location: Jetty Description: Employees exposed to hazards from forklift movement, marine hoses Description: Provide designated walkway in/out of jetty area Benefit: Creating safe working area for the employees ZONE : 2
Criteria 5 : STANDARDIZATION
5S Manual 5S checklist MPC QE/5S Booklet
Criteria 6 : ACHIEVEMENTS & IMPACTS
KPI Results Innovation (I) Quality : 1. ADO Jetty Manifold Upgrading 2. One Stop Center for Drivers HP/Pass collection, DT and Loading Instruction (2Q 2021) Environment : 1. Rainwater harvesting for Tank Truck Loading Rack & Driver’s Toilet (3Q 2021) 2. Water recycling from hand washing to flushing system at driver’s toilet (3Q 2021) 3. Used Cooking Oil Recycling Campaign (3Q 2021) 4. Solar Panel for Parking & Perimeter lighting (4Q 2021) OHS: 1. LIFO system OSRE Cabin (1Q 2021) 2. Fire-fighting room PPE arrangement (1Q 2021) 3. Smoking area with partition (2Q 2021) 4. Paperless UCUX form (4Q 2021)
2019 5S QE 2020 5S QE 2021 2022 Participate in AQEC With GOLD Medal achievement OVERALL RESULTS
OUR SLOGAN PETRON BLT WITHOUT KAIZEN IS LIKE RUGBY WITHOUT ALL BLACKS
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