1. The Impact of Lean manufacturing on WIL to the productivity of Industry
Introduction
Methodology
Results
Conclusions

2. INTRODUCTION
AIM: A survey to establish the extent to which WIL for Mechanical ENG improves productivity in Industry.(Employment)
Lean Manufacturing systems
Helps to get employment.
Applications and outcomes of each Kaizen Tool by WIL students 5S
3Mudas
8 wastes
4MS
PDCA

3. PRODUCTIVITY MEASUREMENT
Productivity is not only about working hard but
( HARD AND SMART).
An average measure of the efficiency of a production process
= output (product /service) resources consumed :
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4. MANUFACTURING SYSTEMS
Old System
Unilateral Communication Top Down
High Volumes REJECTS
Rework
LEAN
BILATERAL
LOW Volumes of rejects
No rework
Mistakes corrected at point
ZERO Defects
CUSTOMER SATISFACTION

5. LEAN MANUFACTURING Cost-cutting methods
The reduction in waste of resources
Cost-cutting methods
Improving methods of doing tasks
Reducing overhead
Reducing idle time
physical resources
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8. ACHIEVEMENTS Improved plant layouts
Arrange stores using FIFO or LIFO (KANBAN)
Mechanized lifting operations to reduce overloads (MURI)
Convert waste to energy ( Muda)
Un-level workplace (Mura)

9. THE 4M MATERIALS Are the volume and grades of material correct?
Is the brand name and impurities correct ?
Is the inventory adequate?
Is the handling proper and prevents material damage and waste?
Is the WIP abandoned?
Is the storage layout adequate and procedural?

10. THE CAUSE AND EFFECT DIAGRAM
MACHINES AND TOOLS
Are the jigs, fixtures and cutters worn out?
Is the power transmission efficient?
Is the machine vibrating, to what extent?
What damage can that cause? Misalignment, bearing failure?
Cant it be corrected or redesigned?

12. METHOD Can the work standard be upgraded?
Is the method efficient, safe and ensure good product and quality.
Are the temperatures, humidity, and dust conditions adequate (Food Industry).
Is there frequent contact with the previous and next process?

13. MANPOWER An investigation by observation to find out:
If the staff have received adequate training
If their talent is being used
Is the staff motivated to work and improve continuously.
Do Staff have bad attitudes

14. OUTCOMES MAN & Methods MACHINE & Materials Training ( CTC etc.)
Machine knowledge and improved hand skills.
Attitudes changed from bad to good.
Setting standards
Improve the environment
Run smoothly & efficiently
Eliminated unplanned breakdowns
Buffers set anticipating breakdowns.
Fast acting jigs and fixtures (reduced setup time by 12-17%)
Reduced rejects

15. PDCA QUALITY CONCEPTS OBJECTIVES STAUTORY PRODUCT LIABILITY & SAFETY
CHECK
PLAN
MANAGE NON CONFORMITY
IMPROVEMENT
ISO 900O & Total quality
CULTURAL ASPECTS
ORGANIZATIONAL ASPECTS
EMS
Management system management
QUALITY CONCEPTS OBJECTIVES
STAUTORY
PRODUCT LIABILITY & SAFETY
TRAINING FOR QUALITY
DESIGN CONTROL

16. PDCA STATISTICS CHARTS INSPECTION AUDIT AND REVIEWS METROLOGY
CHECK DO
STATISTICS
CHARTS
INSPECTION
AUDIT AND REVIEWS
METROLOGY
QUALITY & SAFETY COSTS
BENCH MARKING
PROCUREMENT
JIT
PROCESS CAPABILITY
PROCESS RELIABILITY
MRP
SERVICING QUALITY
STANDARDS & CONFORMITY

19. CONCLUSION

20. Yoke Wrong Attitude You’re always going to have mistakes.
Blame someone or something else (excuses)
Better training is the answer
60% of Unemployed students have wrong attitudes
Right Attitude
Any kind of mistake people make can be reduced and even eliminated
People make fewer mistakes if they are supported by a system based on the principle that errors can always be prevented
90% of successful students have right attitudes

21. J. ZVIDZAYI MECHANICAL ENGINEER WIL CORDINATOR
THANK YOU
J. ZVIDZAYI
MECHANICAL ENGINEER
WIL CORDINATOR

23. Poka -yoke Mistake-Proofing
Poka-Yoke -prevent mistakes from happening or catches any mistake immediately
Defects occur when mistakes are allowed to reach the customer .
Errors are the Cause.
Defects are the Result
Errors are prevented from happening
Errors are discovered and corrected

24. LEAN MANUFACTURING
Installation of new equipment
Minimizing Tardiness-occurring later than expected
Minimizing Absenteeism
Minimizing Turnover- staff leaving the Organization

25. 2019/01/13

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