CLIENT FENNER DUNLOP
Fenner Dunlop Concrete
Project Scope
The project involved designing and constructing civil and concrete components for Fenner Dunlop's K3 Production Line, ensuring they met industry standards and client needs. The objectives were to boost production capacity, support Fenner Dunlop's growth, and align with their strategic goals. Deliverables included finalized designs, successful construction, and documentation of quality and compliance. The project significantly enhanced Fenner Dunlop's manufacturing capabilities, contributing to their expansion in the conveyor belt industry.
Key components of the project
Design:
Develop detailed designs for all civil and concrete elements required for the K3 Production Line.
Ensure designs meet all relevant industry standards and client specifications.
Engineering:
Provide engineering expertise to support the design and integration of civil and concrete components.
Conduct thorough engineering assessments and validations to ensure structural integrity and functionality.
Construction:
Execute the construction of civil and concrete components in accordance with the approved designs and engineering plans.
Oversee all construction activities to ensure adherence to quality standards, timelines, and safety regulations.
Objectives:
Enhance Fenner Dunlop’s production capabilities to support increased manufacturing demands for conveyor belt products.
Facilitate Fenner Dunlop’s growth and ability to meet the expanding needs of the conveyor belt industry.
Contribute to a significant investment in Fenner Dunlop’s production capacity and infrastructure.
Support Fenner Dunlop’s strategic objectives and market expansion efforts through the successful completion of the K3 Production Line.
DELIVERABLES
Complete and approved designs for civil and concrete elements.
Successful construction and integration of the K3 Production Line’s civil and concrete components.
Documentation of construction processes, inspections, and compliance with quality standards.
The completion of the K3 Production Line represented a major enhancement to Fenner Dunlop’s production capabilities, supporting their strategic goals and facilitating their continued growth and expansion in the conveyor belt industry.
Project Challenges
Challenge
Working within a production facility
Mitigation
By holding detailed planning sessions with all stakeholders to identify potential conflicts and establish clear procedure. Developing a construction schedule that minimises disruptions to existing operations. Consider working during off-peak hours or coordinating shutdown periods if feasible. Maintain open lines of communication with the facility’s management and production teams. Provide regular updates on construction progress and any potential impact to the project. Develop a comprehensive site-specific safety plan that addresses the unique hazards of working within an active production facility. Ensuring that all construction personnel receive training on the facility’s safety protocols and emergency procedures. Implementing measures to control dust and noise, such as using dust suppression techniques and noise-reducing equipment. Planning and manage access routes for construction equipment and materials to avoid interference with production activities. Develop and communicate emergency response procedures tailored to the construction activities and the production facility’s operation. Working closely with the facility’s production team to understand their processes and schedules and adjust construction activities as needed to avoid operational conflicts. Being prepared to adapt construction activities in response to unforeseen changes in the facility’s production requirements.
Challenge
Dust control within a production facility
Mitigation
Modifying production processes to reduce the generation of dust. For example, use wet methods or enclose processes that produce significant dust. Implementing procedures to minimise dust during material handling. By building enclosures or barriers around dust-generating equipment and processes to contain dust within a defined are. Using industrial sweepers to minimise dust on floor surface. Ensuring that the facility is well-ventilated to dilute and remove dust from the air. Provided appropriate PPE, such as dust masks or respirators, to workers exposed to dust. Scheduling high-dust activities during times when they will have the least impact on other operations.
Challenge
Maning
Mitigation
Analysing project requirements and workload to accurately forecast staffing needs and avoid over or under-staffing. Ensuring a safe working environment by adhering to health and safety regulations and providing necessary protective equipment. Implementation of wellness programs and support mental health to reduce absenteeism and improve overall employee well-being. Recognise and reward high performance to boost morale and motivation. Implement collaboration tools to enhance communication and coordination among team members. Develop contingency plans for emergencies, such as sudden staff shortages, to ensure business continuity.
Challenge
Traffic within production building
Mitigation
Design the layout of the production building to create clear pathways for pedestrian and vehicle traffic, reducing cross-traffic and congestion. Established dedicated routes for different types of traffic (e.g., material handling vehicles, personnel, and visitors) to minimize interference. Implementing and enforcing speed limits within the building to reduce the risk of accidents and maintain a safe environment. Coordinated schedules for material deliveries, equipment movements, and personnel shifts to avoid peak traffic times and reduce congestion. Train employees on safe traffic practices, including proper procedures for navigating the building and responding to traffic control signals. Providing and installing safety barriers or guards in areas where pedestrian and vehicle traffic intersect to protect workers and prevent accidents.
Challenge
Safety
Mitigation
By conducting comprehensive risk assessments to identify potential hazards and assess their impact. Regularly update assessments to reflect changes in processes or equipment. Developed and implement risk mitigation plans to address identified hazards. Include specific measures to reduce or eliminate risks. Create detailed safety policies and procedures tailored to the specific needs of the facility. Ensure they cover all aspects of operations, including emergency response, equipment use, and personal protective equipment (PPE). Ensured that all employees are aware of and understand the safety policies and procedures through regular training and communication. Ensuring that all employees have access to and properly use the appropriate PPE for their tasks, such as helmets, gloves, safety glasses, and hearing protection. Performed routine safety inspections to identify potential hazards and ensure compliance with safety standards. Conducting regular safety audits to evaluate the effectiveness of safety policies and procedures and identify areas for improvement. Fostering a strong safety culture by encouraging open communication about safety concerns and recognising safe practices. Maintain accurate records of safety training, inspections, incidents, and compliance activities.
