BEFORE LEAN MANUFACTURING WAS IMPLEMENTED IN THE ENGINEERING WORKSHOPS

Work benches were always cluttered and bad standard of housekeeping present

Work benches were not over laid with a material to protect benches from damages

Almost all cables were either loose, unsupported, hanging or causing a tripping hazard

Machining area safety screens were torn and badly damaged

Practices with regards to storage of items was not effective nor safe.

Crawl beam in workshop was not well maintained and possessed no corrosion

resistant coating in certain areas.

Workshop walls were full of dust and not clean nor presentable: bad housekeeping and workforce not taking ownership of their

workshop

Another pic showing state of walls in workshop prior to been cleaned and painted.

Bad safety practices with regards to this issue where a charging station was in place but with

no signage nor protection to cables etc

Safety signage in workshop was haphazardly applied in most cases and void in others.

Machinery in workshop did not possess any SOP for operator to familiarize himself/herself

with prior to use of such machinery.

Safety signage was not maintained resulting in signage which was broken been displayed in

workshop areas.

Floor area in machining area prior to revamp

Work shop floor area and scale charge area before revamp

Work shop floor area in general prior to workshop revamp

Workshop floor demarcation and condition prior to refurbishment

Workshop floor demarcation and condition prior to refurbishment

Condition of workshop walls prior to revamp and also the paper notes and communiques

stuck all over windows.

Front wall area of engineering stores prior to revamp.

AFTER LEAN MANUFACTURING WAS IMPLEMENTED

All machinery in workshops was degreased/cleaned and painted: This pic was

taken prior to floors been painted.

Work benches were overlaid with conveyor material and lin bins are been utilized to tore

spare parts been worked with neatly. Workshop rules have been put in place to

maintain housekeeping on workbenches and workshop area in its entirety. New rubber,

non slip floor mats were purchased and placed alongside all work benches.

All loose and hanging cables in workshop were placed and secured onto appropriate cable trays

SOP Placed at pedestal grinder Safety signage pertaining to pedestal grinders placed at pedestal grinder area

Pedestal drill showing SOP for machinery Drill press SOP

Large 3m bed lathe with SOP attached Metal lathe SOP placed at machinery

12V battery operated scale charging area shows the plug box installed and signage to communicate voltage and usage of charging

station

Demarcated storage area on floor for incoming spares and parts

Front wall of engineering stores area after it was painted

All DBs were locked out and relevant signage placed. Emergency pull stop tag installed in case energy has to be shut off in emergency. All locks

are registered and numbered and authorised personnel allocated with authority to open

these panels.

Picture showing workshop floors new Another view of workshop floor demarcations,

demarcations and new machining areas yellow safety screens in background

yellow safety screens installed, workbench floor matting

Newly installed safety screens cordoning off the machining area with newly installed

safety signage for machining area

Something a little different: We have installed x4 colour coded bins which have been allocated to various waste i.e Yellow=recycled materials (plastic bottles, glass bottles etc) Blue= paper, cardboard and plastic; Green=Organic items

(Food stuff and containers) and black=Oil waste (Oily rags, containers containing sediments of oil etc). Each bin has been tagged with signage

to direct person(s) to correct bin.

Side view of newly installed safety screen at machining area

View from inside the machining area showing the revamped area after sorting and shining

Another view from inside machining area showing storage unit for materials used for

machining. Not visible in picture but the machinist went as far as to make tags for

different sized materials and now stores his material according to sizes on the storage

unit.

View of our large 3m bed lathe after sort and shine. Note the SOP once again attached to the

machinery.

View of the workshop walls after painting and neatened up cable trunking

All lighting fixtures were replaced or repaired where damaged, cabling neatened and

fluorescent tubes replaced where required.

Our new drill press recently acquired with an SOP attached to piece of machinery

All machinery has been cleaned and our newly appointed turner has been very responsible in

keeping his machinery this way at all times.

Another picture showing electrical cables which were neatly secured to appropriate

cable trays within workshop area

More cabling neatly and securely attached and run onto appropriate cable trays within the

machine area of workshop

Workshop rules and standard practices in general i.e housekeeping, ppe, storage etc

Workshop rules and standard practices in general i.e housekeeping, ppe, storage etc

Pic of the Yara safe by choice signage installed at entrance to engineering mess

room and our new continuous improvement board

Picture of our notice boards installed: from left to right, Dept Stats board, general notices, safety

board and then a little colour was added by installing some posters above the notice

boards

GENERAL PICTURES OF WORKSHOP REFURBISHMENT AFTER COMPLETION