MONDI - Safer Environments For Assets And Workers

#1 GLOBAL KRAFT PAPER MANUFACTURER

Mondi is a global leader in packaging and paper, contributing to a better world by making innovative packaging and paper solutions that are sustainable by design. Our business is fully integrated across the value chain – from managing forests and producing pulp, paper and plastic films to developing and manufacturing effective industrial and consumer packaging solutions. Sustainability is at the centre of our strategy and intrinsic in the way we do business. We lead the industry with our customer- centric approach, EcoSolutions, where we ask the right questions to find the most sustainable solution.

Mondi Group has preferred Wipelot for electronic occupational health and safety solutions.

In this project, Wipelot focused on 3 main areas after analyzing the customer’s requirements:

• Minimizing the risk of accidents at Mondi’s manufacturing facilities in İzmir and Adana
• Implementing devices with audio-visual warning signals in a loud factory environment
• Installing the solution without disrupting the workflow and efficiency

Key benefits of SAFEZONE solution;

1. Minimizing potential injuries and material damages by preventing forklift accidents
2. Maintaining a safer environment for employees
3. Improving work efficiency

LARGE VOLUME AND OPERATIONAL SIZE

The indoor area of Mondi’s manufacturing facilities in İzmir and Adana is approximately 160,000 m2 (4 factories in total). Within this area, the forklift operators, machine operators and personnel work in collaboration with the aim of increasing efficiency. According to the statistics, a typical forklift travels 38 miles/day in a manufacturing area.

The customer’s initial requirement was to maintain the workflow and efficiency by preventing potential accidents and injuries. In order to achieve this, the operational workflow of the forklifts and employees was brought out. The next challenge was determining the blind spots and junctions at the facility where the most of the accidents occurred.

Finally, a compact, easy to use personnel tag was needed instead of a tag with a neck strap. The new tag had to be small, practical and easily attachable to personnel’s clothes or shoes.

MAINTAINING A SAFER ENVIRONMENT FOR PERSONNEL AND ASSETS IN THE WORKPLACE

In order to maintain the workflow and efficiency, Safezone devices were deployed on every forklift in the manufacturing facility, where warning and danger zones were defined to each device using metric expressions. In this way, Safezone device creates a 360-degree virtual safety zone for each forklift, and sends a 2-stage warning signal in case a forklift, personnel or an equipment violates this zone.

In addition to Safezone devices on the forklifts, readers were also installed at certain areas and junctions regarded as “blind spots”, where the most of the accidents occurred. This system, which involves 2-stage forklift decelerations in addition to warning signals, maintained a safer environment for both the pedestrians and the forklifts.

As a solution for the neck strap personnel tags, a compact mobile device, which can be easily attached to work shoes, was designed. With these new shoe tags, the personnel did not need to carry the tags with them in order for Safezone System to detect their exact location.

With an additional reader deployed on the forklifts, the personnel are automatically registered to the vehicle, preventing false alarms during driving. Wireless Charger Stations were deployed in the changing rooms, where each personnel can check the battery level of his/her tag regularly.IIn summary, by using Safezone System:

The pedestrians who violated the 360-degree safety zone of the forklifts were warned by UWB based tags

The forklift drivers received an audial-visual warning signal for the blind spots, and in case a pedestrian or another forklift violated their 360-degree safety zone.

Potential forklift collisions were avoided with the help of “2-stage forklift deceleration mechanism” that minimizes risky conditions.

Using Safezone Collision Warning System, a safer environment was achieved without disrupting the workflow. Personnel injuries and material damages due to accidents were prevented. Thus, the workforce and financial losses were minimized.

Safezone represents the technology, innovation, know-how and experience gained since 2005.

Safezone creates an extensive electronic ecosystem in facilities, to which the new employees, machines and equipment can quickly adapt.

The personnel tags used in Safezone solution are user friendly, durable (are not affected by harsh conditions) and can be used for up to 6 months with a single charge. Wipelot technical team provides full service and support to its customers before, during and after sales.

Customers who use Safezone Collision Warning System can access to Wipelot’s other products and services with less financial investment.