2016 Maintenance Innovation Challenge MAK Mast boom lift for wash rack operations PROBLEM STATEMENT BENEFITS Problem: Extensive wash rack operations in view of retrograding and repair requirements, also during winter season resulting in a high accident risk for cleaning personnel. Two serious accidents already occurred during the past 12 months. Scope: The project focuses on the improvement of safety during wash rack operations, especially while climbing onto and off heavy equipment. Achieved Goal: Reduced safety risk to a minimum in order to prevent accidents. Reduction of cost intensive accidents and potential handicaps for our employees, in conjunction with a way better work environment for our cleaning personnel. Furthermore, ergonomics are significantly improved and the process is way safer and faster. Return on Investment (ROI): Primarily intangible, while reducing the accident risk to a minimum, while also improving ergonomics may result in mid-term savings. However furthermore considerable are the tangible savings of roughly $ 9,000 annually (pending work load), which will amortize investment within 4 years. TECHNOLOGY SOLUTION GRAPHIC BEFORE AFTER Maintenance Activity Kaiserslautern procured a mast boom lift with bucket which drastically reduced the risk of accidents. The worker easy reaches all recessed or embedded areas on the equipment as well as high surfaces like roof structures. All process steps can be worked in a safe manner. Up and down stepping/climbing by using steps and walking on top of Vehicles, e.g. Tank trucks, are nearly eliminated. Furthermore, while eliminating the accident risk and utilizing procured equipment the man hours required for agricultural cleaning was reduced (cost avoidance). Instead of walking down/up and relocating scaffolds, stepladders and high-pressure fresh water lances, the worker is be able to steam clean surfaces all at once, while lifting or turning the boom to whatever spot required.