(1) Before lean manufacturing, the engineering workshops were very cluttered and unorganized, with safety hazards like loose cables, damaged safety screens, and poor signage. (2) After implementing lean practices, the workshops were thoroughly cleaned and organized, with standardized work areas, clear safety signage, and proper storage of equipment and parts. (3) Additional improvements included installing cable trays, painting walls, and implementing 5S practices like clear demarcation and labeling of storage areas.

1. 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

2. 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.
Workshopwallswere full of dust and not clean
nor presentable: bad housekeeping and
workforce not taking ownership of their
workshop
Anotherpicshowingstate 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

3. Safety signage in workshop was haphazardly
applied in most cases and void in others.
Machinery in workshop did not possess any
SOPfor operatorto familiarize himself/herself
with prior to use of such machinery.
Safetysignage 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

4. 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.

5. 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 linbins are beenutilized 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
placedand securedonto appropriate cable trays

6. 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

7. 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 installedin case
energyhas to be shut off in emergency.All locks
are registered and numbered and authorised
personnel allocated with authority to open
these panels.

8. Picture showing workshop floors new
demarcations and new machining areas
yellow safety screens in background
Another view of workshop floor demarcations,
yellowsafetyscreensinstalled,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

9. 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.

10. 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

11. Pic of the Yara safe by choice signage
installed at entrance to engineering mess
room and our newcontinuous 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

12. GENERAL PICTURES OF WORKSHOP REFURBISHMENT AFTER COMPLETION