An investigation into whether total productive maintenance is effectively applied at an automotive plant
- Authors: Wentzel, Louis
- Date: 2012
- Subjects: Production management , Automobile industry and trade
- Language: English
- Type: Thesis , Masters , MBA
- Identifier: vital:8902 , http://hdl.handle.net/10948/d1020994
- Description: For many manufacturing companies, equipment is the largest capital investment andeffective maintenance of these assets can impact on profitability. It extends equipment life, improves equipment availability and retains equipment in proper condition. Conversely, poorly maintained equipment may lead to more frequent equipment failures, poor utilisation of equipment and delayed production schedules. Malfunctioning equipment may result in scrap or products of poor quality. Total productive maintenance (TPM) is one of the most popular concepts for improving process dependability (Nakajima 1988). It focuses on increasing the effectiveness of maintenance which is commonly measured by the overall equipment effectiveness (OEE). Ford Struandale Engine Plant (FSEP) applies lean manufacturing through its Ford Production System (FPS) which consists of twelve elements. One element of FPS is Ford Total Productive Maintenance (FTPM) with the objective to maximise the overall effectiveness of plant facilities, equipment, processes and tooling through the focused efforts of work groups and the elimination of the major losses associated with manufacturing equipment. The concern for FSEP management was that although FTPM is implemented, the OEE data revealed that equipment availability targets are not achieved. The researcher identified a gap to investigate the reasons for the poor performance. A literature study was conducted to search for relevant information on the subject. A questionnaire was constructed from the theoretical information and a survey was conducted. After data collection the results were captured and analysed. The researcher made conclusions based on the data and made recommendations. The main findings were that autonomous maintenance is not functioning well, spares management is not good and the Computerised Maintenance Management System is underutilised. The recommendations were that these issues must be addressed.
- Full Text:
- Date Issued: 2012
- Authors: Wentzel, Louis
- Date: 2012
- Subjects: Production management , Automobile industry and trade
- Language: English
- Type: Thesis , Masters , MBA
- Identifier: vital:8902 , http://hdl.handle.net/10948/d1020994
- Description: For many manufacturing companies, equipment is the largest capital investment andeffective maintenance of these assets can impact on profitability. It extends equipment life, improves equipment availability and retains equipment in proper condition. Conversely, poorly maintained equipment may lead to more frequent equipment failures, poor utilisation of equipment and delayed production schedules. Malfunctioning equipment may result in scrap or products of poor quality. Total productive maintenance (TPM) is one of the most popular concepts for improving process dependability (Nakajima 1988). It focuses on increasing the effectiveness of maintenance which is commonly measured by the overall equipment effectiveness (OEE). Ford Struandale Engine Plant (FSEP) applies lean manufacturing through its Ford Production System (FPS) which consists of twelve elements. One element of FPS is Ford Total Productive Maintenance (FTPM) with the objective to maximise the overall effectiveness of plant facilities, equipment, processes and tooling through the focused efforts of work groups and the elimination of the major losses associated with manufacturing equipment. The concern for FSEP management was that although FTPM is implemented, the OEE data revealed that equipment availability targets are not achieved. The researcher identified a gap to investigate the reasons for the poor performance. A literature study was conducted to search for relevant information on the subject. A questionnaire was constructed from the theoretical information and a survey was conducted. After data collection the results were captured and analysed. The researcher made conclusions based on the data and made recommendations. The main findings were that autonomous maintenance is not functioning well, spares management is not good and the Computerised Maintenance Management System is underutilised. The recommendations were that these issues must be addressed.
- Full Text:
- Date Issued: 2012
Evaluation of critical factors influencing project success at an automotive OEM in the Eastern Cape
- Authors: Williams, Dion Williams
- Date: 2012
- Subjects: Project management -- South Africa -- Eastern Cape , Automobile industry and trade
- Language: English
- Type: Thesis , Masters , MBA
- Identifier: vital:8921 , http://hdl.handle.net/10948/d1021121
- Description: This study aimed to evaluate the critical factors influencing project success at an automotive OEM in the Eastern Cape. The main purpose of this study was to evaluate the critical success/failure factors in project management at an automotive original equipment manufacturer (OEM) and to compare the results to similar studies conducted in various industries and under different socio-economic, political and cultural conditions. The research methodology for this study included a literature review of previous studies as well as insights from various authors highlighting points deemed crucial for project success. A survey was conducted at an automotive OEM to determine which factors had the greatest influence on project success; respondents were asked to rank their views on a Likert Ranking Scale. An online survey was used to capture all responses. The data collected was analysed using statistical software (Statistica Version 10.0). The empirical study was conducted on 52 employees involved in projects at the OEM; the study was carried out across various departments including Purchasing, Logistics, Quality, Engineering, etc. The final process of the study included an evaluation of findings. On the basis of the survey responses received, it was possible to identify critical success factors in project management that are related to the automotive OEM. These results were used to draw conclusions and develop various recommendations. The conclusions centered on the project success factors defined in the survey. The results were then compared to previous studies, and discrepancies between survey findings of the current study and those of past studies were discussed. The recommendations focused on the top three items identified in each factor group. The results of both past studies, as well as the present study highlight the crucial role the project manager plays in project success. Good co-ordination skills, efficient management of resources and effective leadership were identified as key characteristics of successful project managers. Proper communication was identified as one of the most crucial points in project teams. This study revealed that the ability of the project team to handle unexpected crisis is also an important contributing factor towards project success, along with effective monitoring. Top management support was the most crucial factor towards project success in the factors related to the organisation; this is similar to studies done by previous authors.
- Full Text:
- Date Issued: 2012
- Authors: Williams, Dion Williams
- Date: 2012
- Subjects: Project management -- South Africa -- Eastern Cape , Automobile industry and trade
- Language: English
- Type: Thesis , Masters , MBA
- Identifier: vital:8921 , http://hdl.handle.net/10948/d1021121
- Description: This study aimed to evaluate the critical factors influencing project success at an automotive OEM in the Eastern Cape. The main purpose of this study was to evaluate the critical success/failure factors in project management at an automotive original equipment manufacturer (OEM) and to compare the results to similar studies conducted in various industries and under different socio-economic, political and cultural conditions. The research methodology for this study included a literature review of previous studies as well as insights from various authors highlighting points deemed crucial for project success. A survey was conducted at an automotive OEM to determine which factors had the greatest influence on project success; respondents were asked to rank their views on a Likert Ranking Scale. An online survey was used to capture all responses. The data collected was analysed using statistical software (Statistica Version 10.0). The empirical study was conducted on 52 employees involved in projects at the OEM; the study was carried out across various departments including Purchasing, Logistics, Quality, Engineering, etc. The final process of the study included an evaluation of findings. On the basis of the survey responses received, it was possible to identify critical success factors in project management that are related to the automotive OEM. These results were used to draw conclusions and develop various recommendations. The conclusions centered on the project success factors defined in the survey. The results were then compared to previous studies, and discrepancies between survey findings of the current study and those of past studies were discussed. The recommendations focused on the top three items identified in each factor group. The results of both past studies, as well as the present study highlight the crucial role the project manager plays in project success. Good co-ordination skills, efficient management of resources and effective leadership were identified as key characteristics of successful project managers. Proper communication was identified as one of the most crucial points in project teams. This study revealed that the ability of the project team to handle unexpected crisis is also an important contributing factor towards project success, along with effective monitoring. Top management support was the most crucial factor towards project success in the factors related to the organisation; this is similar to studies done by previous authors.
- Full Text:
- Date Issued: 2012
Factors which affect the levels of automation in an automotive final assembly plant
- Authors: Pillay, Prabshan
- Date: 2012
- Subjects: Process control -- Automation , Automation , Automobile industry and trade
- Language: English
- Type: Thesis , Masters , MBA
- Identifier: vital:8833 , http://hdl.handle.net/10948/d1019800
- Description: In the global automotive industry there is a drive toward integration of autonomous and human operated equipment. Monfared and Yang (2006:546) suggest that this dynamic requirement could be met with elements to be investigated in a research paper. Current investigations show a gap in management not having a guideline which can be used to help decide between automation versus human capital in the planning of new production facilities in the automotive assembly plant. (Skjerve and Skraaning, 2004:3). The purpose of this research is to determine what factors affect this decision-making process. In order to carry out this research, an in-depth literature review was conducted using various sources. The sources included, but were not limited to, interviews at assembly plants, the Nelson Mandela Metro University library, various e-journals and the internet. The literature review led to the finding of the factors which affect Levels of Automation (LOA) and to the development of the research instrument which was used to measure the impact of those factors. The results of fifty-two (52) respondents were then analysed and used as evidence to support the three hypotheses proposed. As a result of completing the above procedure the following hypotheses were supported. The greater the level of technology and the lower the skills of employees the greater the level of automation in an automotive assembly plant to be used. The greater the complexity of the assembly processes the lower the level of automation in an automotive assembly plant to be used. The higher the flexibility the greater the level of automation in an automotive assembly plant to be used. This means that managers and supervisors of assembly plants should consider the level of technology and skills of employees, flexibility and complexity during the design stages of an automotive assembly line as these factors will affect profitability by reducing waste, improve quality as well as allow for flexibility in customer demand in terms of volumes and product variance.
- Full Text:
- Date Issued: 2012
- Authors: Pillay, Prabshan
- Date: 2012
- Subjects: Process control -- Automation , Automation , Automobile industry and trade
- Language: English
- Type: Thesis , Masters , MBA
- Identifier: vital:8833 , http://hdl.handle.net/10948/d1019800
- Description: In the global automotive industry there is a drive toward integration of autonomous and human operated equipment. Monfared and Yang (2006:546) suggest that this dynamic requirement could be met with elements to be investigated in a research paper. Current investigations show a gap in management not having a guideline which can be used to help decide between automation versus human capital in the planning of new production facilities in the automotive assembly plant. (Skjerve and Skraaning, 2004:3). The purpose of this research is to determine what factors affect this decision-making process. In order to carry out this research, an in-depth literature review was conducted using various sources. The sources included, but were not limited to, interviews at assembly plants, the Nelson Mandela Metro University library, various e-journals and the internet. The literature review led to the finding of the factors which affect Levels of Automation (LOA) and to the development of the research instrument which was used to measure the impact of those factors. The results of fifty-two (52) respondents were then analysed and used as evidence to support the three hypotheses proposed. As a result of completing the above procedure the following hypotheses were supported. The greater the level of technology and the lower the skills of employees the greater the level of automation in an automotive assembly plant to be used. The greater the complexity of the assembly processes the lower the level of automation in an automotive assembly plant to be used. The higher the flexibility the greater the level of automation in an automotive assembly plant to be used. This means that managers and supervisors of assembly plants should consider the level of technology and skills of employees, flexibility and complexity during the design stages of an automotive assembly line as these factors will affect profitability by reducing waste, improve quality as well as allow for flexibility in customer demand in terms of volumes and product variance.
- Full Text:
- Date Issued: 2012
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