At TATA Steel Port Talbot, we’re taking groundbreaking steps to revolutionise hydraulic hose safety. Our commitment to worker safety and operational efficiency has led us to implement innovative solutions that are setting new standards in the industry. Let’s dive into how we’re mitigating risks and improving the safety of our plant through cutting-edge technology and strategic partnerships.

The Challenge: Enhancing Hydraulic Hose Safety

Hydraulic hoses play a crucial role in our operations at Port Talbot. They’re the lifelines of our hydraulic systems, powering various equipment and machinery essential for steel production. However, these hoses are subject to extreme conditions, including high pressures, temperatures, and constant wear and tear. The potential for hose failure poses significant risks to both our workers and our operations.

Ryan Davies Engineering Manager, a key figure at TATA Steel Port Talbot, recognised the need to improve the safety inspection regime for all hydraulic hoses installed in our Hot Mill. This initiative wasn’t just about maintaining equipment; it was about safeguarding lives and ensuring uninterrupted production.

Our Innovative Solution: Asset Tagging with QR Codes

To address this challenge, we’ve partnered with Control Gear, a leading manufacturer and supplier of pressurised hydraulic hose and compressor systems based in South Wales. Together, we’ve developed a groundbreaking system that uses QR codes to improve hose safety and performance.

Here’s how it works:

1. QR Code Generation: We’ve collaborated with Asset Tagged Limited to design a new software application powered by QuickBase. This system enables the team at Control Gear to generate unique QR codes for each hydraulic hose.
2. Industrial Strength Tagging: These QR codes are printed on industrial-strength tags that can withstand the harsh environments our hoses are exposed to. We’ve partnered with Brady Inc., owners of Scafftag, to ensure the durability of these tags.
3. Comprehensive Information: Each QR code, when scanned, provides instant access to critical information about the hose, including:

• Original certificate of conformity
• Date of manufacture
• Date of installation
• The location of each hose
• Maintenance history

1. Easy Identification and Location: The system allows our maintenance engineers to quickly identify and locate specific hoses for annual inspections or immediate maintenance or replacement.
2. Seamless Handover: The QuickBase-powered system facilitates a smooth handover of hoses from Control Gear to TATA Steel, helping us manage planned preventative maintenance during shutdowns more effectively.

The Development Process: A Collaborative Effort

The development of this system was a true collaborative effort. The team at Asset Tagged worked closely with both TATA Steel and Control Gear to map and develop the entire process from cradle to grave. This comprehensive approach ensures that both organisations gain visibility of all hoses on site.

Anastasia Pazechka, the systems architect and QuickBase developer, worked directly on-site at TATA Steel Port Talbot with Control Gear to fine-tune the system. This hands-on approach was crucial in ensuring that the solution met our specific needs and could integrate seamlessly into our existing processes.

Craig Gillard from Control Gear emphasised that having the developers on-site, working directly with Ashley Jones and the team, was a major factor in the success of the asset management software. This close collaboration allowed for real-time adjustments and rapid improvements based on practical feedback from the end-users.

The Impact: Transforming Hose Management

After 12 months of using the system, the results have been nothing short of transformative. We now have complete visibility of every hydraulic hose manufactured and installed over the past year and a half. This level of tracking and traceability was previously unimaginable and was traditionally managed using excel spreadsheet that were prone to error and data entry mistakes.

The benefits of this system extend far beyond mere record-keeping:

1. Enhanced Safety: By having detailed information about each hose readily available, we can proactively identify and replace hoses that are nearing the end of their service life, significantly reducing the risk of unexpected failures.
2. Improved Maintenance Efficiency: Our maintenance teams can now quickly locate and inspect specific hoses, streamlining the maintenance process and reducing downtime.
3. Better Resource Management: With accurate data on hose lifecycles, we can optimise our inventory management and maintenance schedules, leading to cost savings and improved operational efficiency.
4. Compliance and Quality Assurance: The system helps us maintain rigorous standards and easily demonstrate compliance with safety regulations.
5. Reduced Environmental Impact: By preventing hose failures, we minimise the risk of hydraulic fluid leaks, protecting both our workers and the environment.

Looking Ahead: Expanding the System

Encouraged by the success of this initiative, we’re now in the process of inspecting all existing hoses in the plant to retrofit them with QR codes. This will bring our entire inventory of hydraulic hoses under this advanced management system, further enhancing safety and efficiency across our operations.

Ian Fielding, Director and founder of Asset Tagged Limited, emphasised the importance of having a robust tagging solution that matches the durability of the software. This holistic approach ensures that every aspect of the system can withstand the demanding conditions of our steel plant.

The Broader Impact: Setting New Industry Standards

Chris Morris – Director of Control Gear Hydaulics states “Our innovative approach to hydraulic hose management is not just improving operations at Port Talbot; it’s setting new standards for the entire industry. By demonstrating the effectiveness of this system, we’re paving the way for other manufacturing facilities to adopt similar practices, potentially saving lives and improving efficiency across the sector”.

The success of this project highlights several key factors that can drive innovation in industrial safety:

1. Cross-Industry Collaboration: By bringing together experts from steel manufacturing, hydraulic systems, and software development, we’ve created a solution that addresses real-world challenges comprehensively.
2. Leveraging Technology: The use of QR codes and a robust software platform shows how existing technologies can be adapted to solve complex industrial problems.
3. On-Site Development: Having developers work directly in the plant environment ensured that the solution was tailored to the specific needs and challenges of our operations.
4. Continuous Improvement: The system’s success has motivated us to expand its application, demonstrating our commitment to ongoing safety enhancements.

The Role of Leadership in Driving Innovation

It’s important to acknowledge the role of leadership in driving this innovation. Ryan Davies of TATA Steel has been the driving force behind this initiative, recognising the potential for technology to transform our safety practices. His vision and commitment to worker safety have been instrumental in bringing this project to fruition.

Conclusion: A New Era of Hydraulic Hose Safety

The implementation Asset Tagged a QR code-based asset management system for hydraulic hoses at TATA Steel Port Talbot marks a significant milestone in industrial safety and efficiency. By combining cutting-edge technology with strategic partnerships and a commitment to continuous improvement, we’ve created a solution that not only enhances safety but also improves operational efficiency.

As we continue to expand and refine this system, we’re not just improving our own operations; we’re setting a new standard for the industry. Our success demonstrates that with innovative thinking, collaboration, and a commitment to safety, it’s possible to overcome long-standing challenges in industrial environments.

The journey to perfect this system has been long and challenging, but the results speak for themselves. We now have a robust, reliable, and efficient way to manage our hydraulic hoses, ensuring the safety of our workers and the smooth operation of our plant. As we look to the future, we’re excited about the potential to further refine and expand this system, continuing to lead the way in industrial safety and efficiency