Preparing today’s Engineers for tomorrows challenge

WHAT
DO YOU
THINK
Challenges for Manufacturing Engineers !

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Civil , tasteful & relevant
Engineering

So many questions ………………………….

What
When
Where
Who
Why
5 Wife
How
1
Husband
Like in all jobs, engineers come in all
shapes and sizes.
No one quality will make you a good
engineer.
Engineering is a field that requires many
people with different skills to work
together to solve complex problems.
There's no precise formula that will tell
you if you have what it takes, but here are
some personal qualities that will help you
become a successful engineer.
Remember that not all these are
necessary, but do keep these in mind
when deciding if you see engineering in
your future.
What is Engineering ?
Engineering is the process of producing a
technical product or system to meet a
specific need.

Engineer basic requirements ?

Basically, engineers are problem-solvers.
They put scientific knowledge to practical use,
applying science and math to solve problems
creatively. They are involved with the design,
construction and operation of everything from
bridges to computer chips to mountain bikes to
roller coasters.
In fact, without engineers, our modern way of life
would not be very modern at all!
 Which are you?
Electrical/Electronics
Mechanical
Mechatronics
We call all of them ENGINEER

Challenges of Today’s Engineers

45% Departmental Co-operations

42% Lack of knowledge
13% Insufficient Time

A survey carried out on 60 employee from 8 companies

 What Today’s Engineer DO NOT KNOW

100% Difference between Process & Operations

100% Importance or work measurement
100% Definition of Line Balance Loss of 20%
100% Types of motions in every operations
83% What is the meaning of productivity
83% Proper usage of process flow chart
83% Identifying the different flow chart symbol
83% What is Ergonomics and effect to an operation
66% 6 types of processing waste
50% Purpose of standard time
50% What is external and internal set-up

The survey carried out on 60 employees from 8 companies

What Qualities do successful engineers have?

 Strong in mathematics and science

 Good communication skills

 Highly analytical and detail oriented

 Imaginative and creative

 Enjoy working in teams

 Enjoy building or improving the way things work

Analytical Skills
We make decisions everyday, but the decision
engineers make may determine if a bridge can
hold a car or if it will collapse under its own
weight. That's why engineers have to be able to
analyze a situation and see the factors involved
that will help in making informed decisions.

Problem Solving Skills

Engineers make a living by applying knowledge
in ways that can benefit people. In the real world,
it's not always that easy. Anything that can go
wrong will go wrong. When they run into dead
ends, engineers have to find better ways of doing
things or come up with a totally different
approach. The ability to solve problems is key
part of engineering.
Communication Skills
Like in any other job, engineers have to be able to
get along with others. Engineers must talk to
other engineers to effectively solve problems. No
one, no matter how smart, can do everything by
themselves. Two heads are better than one. An
engineer also have to talk to the public to make
sure their needs are met.

Creativity
In facing challenges, you will be encouraged to
"think outside of the box" and explore new
possibilities. This need to creativity makes
engineering even more exciting.
Engineer challenges _ Did not undergo Manufacturing Tools

TECHNICAL MANAGEMENT

 Industrial Engineering Techniques

 CREATIVE THINKING (TRIZ)

 SIX SIGMA  LEAN MANUFACTURING

 FMEA / SPC / MSA / DOE  KAIZEN / JIT / POKA YOKE

 TIME STUDY / MOST  TPM

 REALIBILITY / MTBF  7 QC TOOLS

 ESD  TQM

 QMS

 QUALITY TOOLS
 In A Simplistic Way ………..Engineer challenges !

Reactive Proactive

You act when you see You choose to act when you see
things in your EYES ! things in your MIND !
…not happened yet
…happened / happening

Base Base
 Best Practice  Knowledge
 Training  Exposures
 Procedure  Experiences
 Common Sense
 In A Simplistic Way ………..Engineer challenges !

How/When to Apply Poka-Yoke / FMEA?

Poka-Yoke FMEA
• Reactive • Proactive

• Existing / On-going • New

Dr Shingo
• Any Process / Case • Key/Core Processes

• Zero Defect • Towards Zero Defect

• Elimination • Prevention

• Individual / Team base • Team base

• Concept • Analytical

Mistakes happen for many reasons, but almost all can be

prevented if we take time to identify when and why they
happen and then take steps to prevent them by using
some methods with consideration to other available
solutions
 In A Simplistic Way ………..Engineer challenges !
Lack of Problem Solving Methodology

A Systematic Approach (SUCCESS)

• Selecting topic Identify problem

S
• Understanding current situation & setting targets Collect fact & set targets
U
C • Creating action plan Define role & roadmap

C
• Carry out analysis Analyze & Identify root cause
E
S • Establishing and implementing proposals Develop countermeasures

S • Studying and confirming effectiveness Confirm results

• Standardization and monitoring Cascade solution

What is Manufacturing Engineering Role ?
Definition:

Engineering applies engineering analysis and techniques

to the production of goods and services. Engineers plays
the most economical and effective ways for an organization.

Engineers also develop training and job evaluation programs

and work-performance standards, and help determine wages and
employee benefits. They work to solve
such problems as high costs, low productivity, and poor product quality.

Their work often requires a knowledge of economics, psychology,

and personnel management.
Industrial engineers works in a wide variety of businesses and
industries, including sales, marketing, information
systems, hospitals, airlines, banks, railroads and social services.

Engineer is an Integration of :
MACHINE + MAN + MATERIAL + MONEY + METHOD
What does Manufacturing Engineer do?

• Figure out how to do things better.

• Design efficient and effective processes and systems

• Saving money through analysis and innovative ideas

• Making the workplace better for fellow workers

• Layout planning of both equipment and labor

• Quickly become expert in manufacturing and production

processes

• Carrying out observation at line site to confirm certain details

• Aware of different cultures needs and challenges of company

What does Manufacturing Engineer do?
Process Oriented  Analyze the process

 Identify unnecessary tasks

 Value-added vs. Non-value-added task
 Identify duplicating task
 Time taken for each activity
 Identify unnecessary tasks

NORMAL NON VALUE

WORK NORMAL ADDED
WORK

 Task which pose as obstacle for process improvement

 Task which will not effect the final product in terms of reliability and
performance
 Task which could be carried out in more productive ways
What does Manufacturing Engineer do?

• Value Added and Non-Value Added  Minimize NVA

Unnecessary
Task • Incidental
A required task before a VA task is performed

Value
• Non Value Added (NVA)
Added Task which does not add ant value to the final product
Non Value
• Value Added (VA)
Task which is required and will add value to the final
product.
Incidental
 Cubic Expectation !
 Self motivated.
 Enthusiasm to learn about emerging technologies,
hardware/software and application.
 Logical approach to problem solving and troubleshooting.
 Result oriented.
 Quick thinking (Speed , Fast & Accurate).
 Work under high pressure environment/situations.
 Good analytical, business communication and time
management skills.
 Leadership skills - Organizing and motivating a group of
engineers.
 Drawing skills - To draw process workflow or schematic
drawings.
 Training and mentoring skills - To train and mentor junior
or fellow engineers or operational staff.
 Good teamwork within organization
Summary
Whatever you decide to do, just remember it's you who should decide,
not your parents, teachers, or friends. Don't let someone tell you can't
be an engineer because of your race or gender.
Engineering is a field wide enough for people of all types.

You should be confident that you can be a good engineer, but you're
probably wondering why you should spend years training to be one.
Summary
Whatever you decide to do, just remember it's you who should decide,
not your parents, teachers, or friends. Don't let someone tell you can't
be an engineer because of your race or gender.
Engineering is a field wide enough for people of all types.

You should be confident that you can be a good engineer, but you're
probably wondering why you should spend years training to be one.

"Whatever your mind can conceive and

believe it can achieve.“
[Napoleon Hill]
 QUOTE
 MALAYSIAN MANUFACTURERS MUST KEEP
PRODUCTION COSTS LOW, INCREASE QUALITY ,
PRODUCTIVITY AND CONTINUE TO AQUIRE NEW
TECHNOLOGIES TO ENSURE THAT THEY DO NOT LAG
BEHIND THEIR COMPETITORS FROM OTHER
COUNTRIES”

• DR.MAHATHIR MOHAMAD,1993
 THE MANUFACTURERS
CHALLENGES

• COST
• QUALITY
• DELIVERY
• PRODUCTIVITY

COST QUALITY DELIVERY

PRODUCTIVITY/ OUTPUT
 CUBIC ELECTRONIC

Preparing today’s Engineers

for tomorrows challenge