Failure of autonomous maintenance program at the Gqeberha food manufacturing plant
- Authors: Moloi, Tshepo
- Date: 2024-12
- Subjects: Automatic control , Process control , Food industry and trade -- South Africa
- Language: English
- Type: Master's theses , text
- Identifier: http://hdl.handle.net/10948/70078 , vital:78290
- Description: The main emphasis of this research is on the identification of the main factors explaining the difficulties and failure of Autonomous Maintenance (AM) program implementation from the year 2018 to 2024. This qualitative study focuses on a Port Elizabeth, South Africa food processing company that has implemented an AM program. The lack of success attained in staff training after the implementation phase drove this investigation. This study was carried out to provide first-hand evidence of the pragmatic difficulties in the execution of the AM program. Three main goals defined the research: first, to find the problems that emerged during the AM implementation; second, to investigate the inadequacy of the training program in equipping workers with the necessary skills and competencies to successfully carry out AM; and thirdly, to get valuable opinions on possible enhancements or alternative approaches to the implementation phase of AM from operators, line leaders, and analysts. There is an existing research vacuum as nothing is known about how training affects the implementation of AM in food processing plants especially in South Africa. Purposive sampling selected thirty persons. Thirteen process operators, nine technical operators, six-line leaders, two preventive maintenance owners, and a senior management representative made comprised the group. Extensive in-person interviews with operators, line leaders, and top management gathered the data. Thematic analysis was used to examine the data even further to pinpoint the main themes that emerged. Six main topics found in this research best capture the difficulties faced by a food processing company using AM. The problems were poor training, limited time and resources, lack of motivation and rewards, ineffective communication, involvement, and accountability; management gave production priority over autonomous maintenance; and there was no culture of dedication. Several factors contribute to the ineffectiveness of the training program in enabling employees with the required skills to implement AM: the lack of practical examples to support theoretical ideas, limited resources, trainers lacking expertise in their respective fields, which limits understanding. The main emphasis of this research is on the identification of the main factors explaining the difficulties throughout the implementation period. Moreover, this research improves the body of information already in use by stressing the inadequacies of the training program in developing important skills. Helping AM operators and line supervisors understand the difficulties they faced is the primary goal of the research. Top executives will be offered the recommendations for improving and maximizing the AM program. Understanding the training needs for operators will help production managers and human resources professionals to guarantee their successful training and efficient application of the program. Operations management experts in academia have thorough understanding of AM including theoretical ideas, pragmatic implementation, and the difficulties using successful strategies. The key limitation was the narrow focus of the research, which mainly looked at people within the production line of the model line to understand the problems that emerged during the implementation of autonomous maintenance. The generalisation of the results to the whole workforce is not achieved due to the exclusion of employees from other areas of the factory. The company wants to start a thorough training program with a cross-functional team to enhance operator communication. The main topics explaining the problems in the training program is another disadvantage. This will be a strong basis for further studies. , Thesis (MBA) -- Faculty of Business and Economic Sciences, Business School, 2024
- Full Text:
- Date Issued: 2024-12
- Authors: Moloi, Tshepo
- Date: 2024-12
- Subjects: Automatic control , Process control , Food industry and trade -- South Africa
- Language: English
- Type: Master's theses , text
- Identifier: http://hdl.handle.net/10948/70078 , vital:78290
- Description: The main emphasis of this research is on the identification of the main factors explaining the difficulties and failure of Autonomous Maintenance (AM) program implementation from the year 2018 to 2024. This qualitative study focuses on a Port Elizabeth, South Africa food processing company that has implemented an AM program. The lack of success attained in staff training after the implementation phase drove this investigation. This study was carried out to provide first-hand evidence of the pragmatic difficulties in the execution of the AM program. Three main goals defined the research: first, to find the problems that emerged during the AM implementation; second, to investigate the inadequacy of the training program in equipping workers with the necessary skills and competencies to successfully carry out AM; and thirdly, to get valuable opinions on possible enhancements or alternative approaches to the implementation phase of AM from operators, line leaders, and analysts. There is an existing research vacuum as nothing is known about how training affects the implementation of AM in food processing plants especially in South Africa. Purposive sampling selected thirty persons. Thirteen process operators, nine technical operators, six-line leaders, two preventive maintenance owners, and a senior management representative made comprised the group. Extensive in-person interviews with operators, line leaders, and top management gathered the data. Thematic analysis was used to examine the data even further to pinpoint the main themes that emerged. Six main topics found in this research best capture the difficulties faced by a food processing company using AM. The problems were poor training, limited time and resources, lack of motivation and rewards, ineffective communication, involvement, and accountability; management gave production priority over autonomous maintenance; and there was no culture of dedication. Several factors contribute to the ineffectiveness of the training program in enabling employees with the required skills to implement AM: the lack of practical examples to support theoretical ideas, limited resources, trainers lacking expertise in their respective fields, which limits understanding. The main emphasis of this research is on the identification of the main factors explaining the difficulties throughout the implementation period. Moreover, this research improves the body of information already in use by stressing the inadequacies of the training program in developing important skills. Helping AM operators and line supervisors understand the difficulties they faced is the primary goal of the research. Top executives will be offered the recommendations for improving and maximizing the AM program. Understanding the training needs for operators will help production managers and human resources professionals to guarantee their successful training and efficient application of the program. Operations management experts in academia have thorough understanding of AM including theoretical ideas, pragmatic implementation, and the difficulties using successful strategies. The key limitation was the narrow focus of the research, which mainly looked at people within the production line of the model line to understand the problems that emerged during the implementation of autonomous maintenance. The generalisation of the results to the whole workforce is not achieved due to the exclusion of employees from other areas of the factory. The company wants to start a thorough training program with a cross-functional team to enhance operator communication. The main topics explaining the problems in the training program is another disadvantage. This will be a strong basis for further studies. , Thesis (MBA) -- Faculty of Business and Economic Sciences, Business School, 2024
- Full Text:
- Date Issued: 2024-12
The influence of interpretation of iso 19011: 2018 guidelines on performing third-party quality audits to promote uniformity and consistency in the audit process
- Authors: Sepeng, Thembekile Debora
- Date: 2024-04
- Subjects: ISO 9000 Series Standards -- Auditing , Quality control -- Auditing , Process control
- Language: English
- Type: Doctoral theses , text
- Identifier: http://hdl.handle.net/10948/64797 , vital:73915
- Description: Third-party quality audits (TPQA) facilitate performance improvement and reliability that give confidence to organisations concerning the process quality of services and products. In South Africa, ISO 9001: 2015 standard certification gained popularity as a requirement in the business tender criteria. While TPQA are crucial for evaluating conformance to industry standards, reportedly numerous organisations share disappointments as their expectations seem no longer realised. Certification faces criticism about its effectiveness in delivering TPQA that add value. Research has shown in some cases that despite the revisions of the ISO 19011: 2011 standard and limited studies conducted TPQA are regarded as added cost activities, and their initial purpose as an impartial tool to ensure quality of deliverables is no longer upheld. Increasingly, because of inconsistencies and unethical practices often observed in the industry, organisations question the significance of TPQA. Hence, the need was identified to determine and explain the influence of the ISO 19011: 2018 standard interpretation on the application of the audit guidelines in performing TPQA, to promote consistency in the audit process. A sequential exploratory mixed-method study was conducted employing a document analysis of the ISO 19011: 2018 standard, semi-structured interviews with the certification managers (CBs) and third-party quality auditors; and a survey questionnaire which was sent to quality practitioners and experts. The findings of the qualitative phases of the study were verified during the quantitative phase. The outcome of each phase of the study informed the development of the data collection instrument in the next phase. Two frameworks were designed: A conceptual framework after the document analysis and an empirical framework based on the interview data. The qualitative findings and quantitative results were integrated before conclusions were drawn and recommendations made. Achieving effective audits requires that an audit programme be established, implemented, monitored, reviewed and improved within the confines of the principles of auditing. The study found that the value of the audit process is limited by the different interpretations of the audit guidelines held by CBs and auditors. Adherence to the principles of auditing particularly, integrity and independence were found as the core of the audit process while their disregard reflected failure of the real intent of auditing. In managing the audit programme the study revealed that the inconsistencies in the audit procedures and documents developed for the auditors were ascribed to some CBs’ personal interpretations. Potential pitfalls are exacerbated by most auditors being contracted across the different bodies, and work according to the different CBs’ processes. The different interpretations of the standard suggest that certain guidelines might be vaguely written, resulting in uncertainties concerning reproducibility of the audit process. Competence featured most so that lack of it was perceived as the main hindrance to the audit process. The study recommends formal consultations among experts and practitioners to reflect on the interpretation of the guidelines to manage the audit programmes, and eliminate root causes and practices affecting the audit process. Also recommended is integration of the study findings into auditor training courses to support standardisation and reduce the variations across and amongst the different CBs and auditors. , Thesis (PhD) -- Faculty of Engineering, the Built Environment, and Technology, School of Engineering, 2024
- Full Text:
- Date Issued: 2024-04
- Authors: Sepeng, Thembekile Debora
- Date: 2024-04
- Subjects: ISO 9000 Series Standards -- Auditing , Quality control -- Auditing , Process control
- Language: English
- Type: Doctoral theses , text
- Identifier: http://hdl.handle.net/10948/64797 , vital:73915
- Description: Third-party quality audits (TPQA) facilitate performance improvement and reliability that give confidence to organisations concerning the process quality of services and products. In South Africa, ISO 9001: 2015 standard certification gained popularity as a requirement in the business tender criteria. While TPQA are crucial for evaluating conformance to industry standards, reportedly numerous organisations share disappointments as their expectations seem no longer realised. Certification faces criticism about its effectiveness in delivering TPQA that add value. Research has shown in some cases that despite the revisions of the ISO 19011: 2011 standard and limited studies conducted TPQA are regarded as added cost activities, and their initial purpose as an impartial tool to ensure quality of deliverables is no longer upheld. Increasingly, because of inconsistencies and unethical practices often observed in the industry, organisations question the significance of TPQA. Hence, the need was identified to determine and explain the influence of the ISO 19011: 2018 standard interpretation on the application of the audit guidelines in performing TPQA, to promote consistency in the audit process. A sequential exploratory mixed-method study was conducted employing a document analysis of the ISO 19011: 2018 standard, semi-structured interviews with the certification managers (CBs) and third-party quality auditors; and a survey questionnaire which was sent to quality practitioners and experts. The findings of the qualitative phases of the study were verified during the quantitative phase. The outcome of each phase of the study informed the development of the data collection instrument in the next phase. Two frameworks were designed: A conceptual framework after the document analysis and an empirical framework based on the interview data. The qualitative findings and quantitative results were integrated before conclusions were drawn and recommendations made. Achieving effective audits requires that an audit programme be established, implemented, monitored, reviewed and improved within the confines of the principles of auditing. The study found that the value of the audit process is limited by the different interpretations of the audit guidelines held by CBs and auditors. Adherence to the principles of auditing particularly, integrity and independence were found as the core of the audit process while their disregard reflected failure of the real intent of auditing. In managing the audit programme the study revealed that the inconsistencies in the audit procedures and documents developed for the auditors were ascribed to some CBs’ personal interpretations. Potential pitfalls are exacerbated by most auditors being contracted across the different bodies, and work according to the different CBs’ processes. The different interpretations of the standard suggest that certain guidelines might be vaguely written, resulting in uncertainties concerning reproducibility of the audit process. Competence featured most so that lack of it was perceived as the main hindrance to the audit process. The study recommends formal consultations among experts and practitioners to reflect on the interpretation of the guidelines to manage the audit programmes, and eliminate root causes and practices affecting the audit process. Also recommended is integration of the study findings into auditor training courses to support standardisation and reduce the variations across and amongst the different CBs and auditors. , Thesis (PhD) -- Faculty of Engineering, the Built Environment, and Technology, School of Engineering, 2024
- Full Text:
- Date Issued: 2024-04
Enablers for lean process sustainability within South African manufacturing industries
- Authors: Roth, Benlloyd Koekemoer
- Date: 2015
- Subjects: Lean manufacturing , Manufacturing processes , Process control
- Language: English
- Type: Thesis , Masters , MBA
- Identifier: http://hdl.handle.net/10948/6591 , vital:21122
- Description: James Womack and his colleagues Daniel Jones and Daniel Roos changed the way western civilization approached manufacturing. In 1990, they published a book called ‘The Machine That Changed the World: The Story of Lean Production’. It was a concept that had slowly filtered from the east but had not made its mark on the manufacturing sector. The concept of lean, born out of the Japanese Toyota Manufacturing System, was first thought to be impossible to duplicate outside of Japan. Since Womack and company popularised this “new” way of producing goods and delivering services it spread across industries finding popularity in the medical, engineering, accounting and especially the manufacturing industries. Over the last few decades lean practices has been synonymous with efficiency, cost reduction, supply chain optimisation and innovative problem solving (Anvari Norzima, Rosnah, Hojjati and Ismail, 2010; Pieterse et al., 2010; Womack et al., 1990). Lean process implementation has been researched in abundance, as has failed attempts at lean implementation. The purpose of this study was to identify and assess enablers of lean sustainability in organisations where lean processes are already being implemented. The literature study found Organisational Culture, Leadership, Employee Engagement and Trade Unions participation as factors that contributed to successful lean implementations. The author developed a model to test Organisational Culture, Leadership, Employee Engagement and Trade Unions as enablers to sustain lean practices in organisations in South Africa’s manufacturing industries. The results proved that Organisational Culture, Leadership and Employee Engagement were considered enablers for lean sustainability. These three enablers have an interlinked relationship and together help sustainability. Lacking just one factor would surely result in unsustainable lean practices. The study was conducted in the quantitative paradigm, as the hypothesised relationship was statistically tested. The data was collected from a homogenous group via an email sent with a link to the questionnaire. The data was statistically analysed with Statistica software and Microsoft Excel.
- Full Text:
- Date Issued: 2015
- Authors: Roth, Benlloyd Koekemoer
- Date: 2015
- Subjects: Lean manufacturing , Manufacturing processes , Process control
- Language: English
- Type: Thesis , Masters , MBA
- Identifier: http://hdl.handle.net/10948/6591 , vital:21122
- Description: James Womack and his colleagues Daniel Jones and Daniel Roos changed the way western civilization approached manufacturing. In 1990, they published a book called ‘The Machine That Changed the World: The Story of Lean Production’. It was a concept that had slowly filtered from the east but had not made its mark on the manufacturing sector. The concept of lean, born out of the Japanese Toyota Manufacturing System, was first thought to be impossible to duplicate outside of Japan. Since Womack and company popularised this “new” way of producing goods and delivering services it spread across industries finding popularity in the medical, engineering, accounting and especially the manufacturing industries. Over the last few decades lean practices has been synonymous with efficiency, cost reduction, supply chain optimisation and innovative problem solving (Anvari Norzima, Rosnah, Hojjati and Ismail, 2010; Pieterse et al., 2010; Womack et al., 1990). Lean process implementation has been researched in abundance, as has failed attempts at lean implementation. The purpose of this study was to identify and assess enablers of lean sustainability in organisations where lean processes are already being implemented. The literature study found Organisational Culture, Leadership, Employee Engagement and Trade Unions participation as factors that contributed to successful lean implementations. The author developed a model to test Organisational Culture, Leadership, Employee Engagement and Trade Unions as enablers to sustain lean practices in organisations in South Africa’s manufacturing industries. The results proved that Organisational Culture, Leadership and Employee Engagement were considered enablers for lean sustainability. These three enablers have an interlinked relationship and together help sustainability. Lacking just one factor would surely result in unsustainable lean practices. The study was conducted in the quantitative paradigm, as the hypothesised relationship was statistically tested. The data was collected from a homogenous group via an email sent with a link to the questionnaire. The data was statistically analysed with Statistica software and Microsoft Excel.
- Full Text:
- Date Issued: 2015
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