Abstract

Teaching and learning in higher institutes of engineering colleges has shifted away from work-integrated learning, which is used to equip students with practical knowledge of real-world problem-solving. Hence, there is a need for industry collaboration in one of the course modules. In this research, the University collaborated with Industry partners to improve the quality of engineering students it produces. The main objective was to produce adaptive graduates; hence, the graduate attribute project was set using industry real problems. The production bottlenecks are caused by misalignment with high-speed primary packaging outputs. Systemic engineering techniques, including process mapping, time and work studies, modelling, simulation, and workflow analysis, were applied to identify performance gaps and inefficiencies across the packaging line. Lean tools such as 5S, Kaizen, and Poka-Yoke were incorporated alongside automation technologies to redesign and improve the system. The proposed solution features sensor-based counting systems, automated defect detection, ergonomically optimized workstations, and synchronized conveyor operations to ensure continuous product flow and accuracy. The integration of GA5 technical analysis with Lean optimization demonstrated measurable improvements in productivity, operational efficiency, and quality consistency. Furthermore, waste levels, rework, and labor strain were significantly reduced, contributing to lower operational costs. Overall, the combined approach establishes a more sustainable, reliable, and high-performance secondary packaging environment aligned with modern food manufacturing standards and continuous improvement objectives.

Keywords: Lean Manufacturing, GA5 Engineering Tools, Packaging Automation, Process Optimization, Productivity Improvement