workshop turn around project
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Transcript of workshop turn around project
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