A model for assessing the anticipated relative financial impact of implementing the tools of lean manufacturing on a manufacturing concern
- Authors: Francis, Merwin
- Date: 2011
- Subjects: Production management , Manufacturing processes , Production planning , Industrial efficiency , Total productive maintenance
- Language: English
- Type: Thesis , Masters , MTech
- Identifier: vital:8972 , http://hdl.handle.net/10948/1326 , Production management , Manufacturing processes , Production planning , Industrial efficiency , Total productive maintenance
- Description: Lean manufacturing has seen its creators, Toyota, rise from insignificance in the middle of the previous century, to the biggest selling car manufacturer in the world today. Another Japanese car manufacturer, Honda, which has also been practising the principles of lean avidly during the last few decades, has also made huge strides towards becoming a dominant force in the car market. These Japanese companies‟ adoption of lean has seen many of their mass producing United States (US) and European counterparts struggle for survival. Maynard (2003:10) predicted that by the end of the decade, at least one of the „Big Three‟ auto makers in the US – Chrysler, Ford, and General Motors (GM) – would be forced to undertake significant restructuring to continue in operation. At the time of this writing all indications are that this prediction will come true. GM is in the process of major shareholding restructuring in an attempt to keep the company afloat, having run up insurmountable debts in the face of the current global economic downturn. Adopting the lean methodology has become a matter of necessity. The continued use of mass production methods alone is no longer viable; companies need to also employ lean methods intelligently in order to remain competitive. This study is regarded as a crucial endeavour to assist operations managers of manufacturing concerns in developing lean implementation strategies which will maximise the benefits to the organization.
- Full Text:
- Date Issued: 2011
- Authors: Francis, Merwin
- Date: 2011
- Subjects: Production management , Manufacturing processes , Production planning , Industrial efficiency , Total productive maintenance
- Language: English
- Type: Thesis , Masters , MTech
- Identifier: vital:8972 , http://hdl.handle.net/10948/1326 , Production management , Manufacturing processes , Production planning , Industrial efficiency , Total productive maintenance
- Description: Lean manufacturing has seen its creators, Toyota, rise from insignificance in the middle of the previous century, to the biggest selling car manufacturer in the world today. Another Japanese car manufacturer, Honda, which has also been practising the principles of lean avidly during the last few decades, has also made huge strides towards becoming a dominant force in the car market. These Japanese companies‟ adoption of lean has seen many of their mass producing United States (US) and European counterparts struggle for survival. Maynard (2003:10) predicted that by the end of the decade, at least one of the „Big Three‟ auto makers in the US – Chrysler, Ford, and General Motors (GM) – would be forced to undertake significant restructuring to continue in operation. At the time of this writing all indications are that this prediction will come true. GM is in the process of major shareholding restructuring in an attempt to keep the company afloat, having run up insurmountable debts in the face of the current global economic downturn. Adopting the lean methodology has become a matter of necessity. The continued use of mass production methods alone is no longer viable; companies need to also employ lean methods intelligently in order to remain competitive. This study is regarded as a crucial endeavour to assist operations managers of manufacturing concerns in developing lean implementation strategies which will maximise the benefits to the organization.
- Full Text:
- Date Issued: 2011
A proposed strategy for the implementation of total productive maintenance at Continental Tyre South Africa
- Authors: Olivier, Christie
- Date: 2007
- Subjects: Continental Tyre South Africa (Firm) , Total productive maintenance , Manufacturing industries
- Language: English
- Type: Thesis , Masters , MBA
- Identifier: vital:8576 , http://hdl.handle.net/10948/799 , Continental Tyre South Africa (Firm) , Total productive maintenance , Manufacturing industries
- Description: For a tyre manufacturing company to compete nationally and internationally, the maximum utilization of their equipment is extremely important. Thus, having a maintenance system in place that will ensure this will be essential. In today’s competitive environment, the need to go further than just scheduling maintenance in accordance with manufacturer’s recommendations as a method of improving productivity and product quality was quickly recognized by those companies who were committed to total quality management programmes. The objective of this study was to propose an appropriate strategy for the implementation of Total Productive Maintenance at Continental Tyre South Africa. To achieve this, the current Total Productive Maintenance (TPM) programme, in the steel stock preparation division in affiliated Continental plants in Otrokovice in the Czech Republic and Puchov in the Slovak Republic was evaluated. A comprehensive literature study was performed on Total Productive Maintenance programmes. A questionnaire was designed based on the guidelines in the literature study in order to establish the effectiveness of implemented TPM programmes. The researcher used the random sampling method of selection and distributed the questionnaire to 62 potential respondents via hand-outs from each plant’s respective heads of departments. 56 completed questionnaires were returned and these were processed and analyzed using Microsoft Office Excel 2003, running on the Windows XP suite of computer packages. The opinions of the various respondents were compared with the guidelines provided in the literature survey, in order to identify how to answer two main questions the author wanted to use as part of selecting an appropriate implementation approach for TPM at Continental Tyre South Africa. These were: • How much are the employees involved and empowered to perform their TPM tasks?; and • How effective is the implemented TPM programme? The following were the main recommendations and conclusions: • The experiences gained by plants like Otrokovice and Puchov must be used as a guideline for introduction and implementation; • The employees that will be required to perform the TPM tasks must be properly trained and they should receive the necessary tools to perform their tasks; • It is essential that everyone throughout the entire manufacturing organization is involved from the start in the development, improvement and maintenance of the TPM programme and that the driving force behind it should be a combination of maintenance, production and quality; and • TPM will achieve it’s objectives if: • The equipment effectiveness can be improved; • Autonomous maintenance is achieved; • Planned maintenance is in place; • Staff are trained in relevant maintenance skills; and • Early equipment management can be achieved.
- Full Text:
- Date Issued: 2007
- Authors: Olivier, Christie
- Date: 2007
- Subjects: Continental Tyre South Africa (Firm) , Total productive maintenance , Manufacturing industries
- Language: English
- Type: Thesis , Masters , MBA
- Identifier: vital:8576 , http://hdl.handle.net/10948/799 , Continental Tyre South Africa (Firm) , Total productive maintenance , Manufacturing industries
- Description: For a tyre manufacturing company to compete nationally and internationally, the maximum utilization of their equipment is extremely important. Thus, having a maintenance system in place that will ensure this will be essential. In today’s competitive environment, the need to go further than just scheduling maintenance in accordance with manufacturer’s recommendations as a method of improving productivity and product quality was quickly recognized by those companies who were committed to total quality management programmes. The objective of this study was to propose an appropriate strategy for the implementation of Total Productive Maintenance at Continental Tyre South Africa. To achieve this, the current Total Productive Maintenance (TPM) programme, in the steel stock preparation division in affiliated Continental plants in Otrokovice in the Czech Republic and Puchov in the Slovak Republic was evaluated. A comprehensive literature study was performed on Total Productive Maintenance programmes. A questionnaire was designed based on the guidelines in the literature study in order to establish the effectiveness of implemented TPM programmes. The researcher used the random sampling method of selection and distributed the questionnaire to 62 potential respondents via hand-outs from each plant’s respective heads of departments. 56 completed questionnaires were returned and these were processed and analyzed using Microsoft Office Excel 2003, running on the Windows XP suite of computer packages. The opinions of the various respondents were compared with the guidelines provided in the literature survey, in order to identify how to answer two main questions the author wanted to use as part of selecting an appropriate implementation approach for TPM at Continental Tyre South Africa. These were: • How much are the employees involved and empowered to perform their TPM tasks?; and • How effective is the implemented TPM programme? The following were the main recommendations and conclusions: • The experiences gained by plants like Otrokovice and Puchov must be used as a guideline for introduction and implementation; • The employees that will be required to perform the TPM tasks must be properly trained and they should receive the necessary tools to perform their tasks; • It is essential that everyone throughout the entire manufacturing organization is involved from the start in the development, improvement and maintenance of the TPM programme and that the driving force behind it should be a combination of maintenance, production and quality; and • TPM will achieve it’s objectives if: • The equipment effectiveness can be improved; • Autonomous maintenance is achieved; • Planned maintenance is in place; • Staff are trained in relevant maintenance skills; and • Early equipment management can be achieved.
- Full Text:
- Date Issued: 2007
The impact of total productive maintenance (TPM) on manufacturing performance at the Colt Section of DaimlerChrysler in the Eastern Cape
- Authors: Ncube, Mfowabo
- Date: 2006
- Subjects: Total productive maintenance , Plant maintenance -- Management , Automobile industry and trade -- South Africa -- Eastern Cape
- Language: English
- Type: Thesis , Masters , MBA
- Identifier: vital:8560 , http://hdl.handle.net/10948/579 , Total productive maintenance , Plant maintenance -- Management , Automobile industry and trade -- South Africa -- Eastern Cape
- Description: Today's successful manufacturing organisations require a significant competitive advantage, hence the need to implement and develop a Total Productive Maintenance (TPM) strategy. This research paper addresses the impact of TPM on manufacturing performance at the Colt production facility (DCSA). A literature survey was undertaken into the elements and benefits of TPM. Questionaires were also sent to all levels of people at the Colt production facility for their views on TPM and the impact, they believe, it has had on manufacturing performance. In conclusion, this research paper has also led to the development of recommendations to improve TPM activities at the Colt production facility. From the research, it was shown that top management support for TPM activities is needed and that training is an essential factor for TPM's success in improving manufacturing performance.
- Full Text:
- Date Issued: 2006
- Authors: Ncube, Mfowabo
- Date: 2006
- Subjects: Total productive maintenance , Plant maintenance -- Management , Automobile industry and trade -- South Africa -- Eastern Cape
- Language: English
- Type: Thesis , Masters , MBA
- Identifier: vital:8560 , http://hdl.handle.net/10948/579 , Total productive maintenance , Plant maintenance -- Management , Automobile industry and trade -- South Africa -- Eastern Cape
- Description: Today's successful manufacturing organisations require a significant competitive advantage, hence the need to implement and develop a Total Productive Maintenance (TPM) strategy. This research paper addresses the impact of TPM on manufacturing performance at the Colt production facility (DCSA). A literature survey was undertaken into the elements and benefits of TPM. Questionaires were also sent to all levels of people at the Colt production facility for their views on TPM and the impact, they believe, it has had on manufacturing performance. In conclusion, this research paper has also led to the development of recommendations to improve TPM activities at the Colt production facility. From the research, it was shown that top management support for TPM activities is needed and that training is an essential factor for TPM's success in improving manufacturing performance.
- Full Text:
- Date Issued: 2006
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