Assessing the impact of the lean manufacturing supplier development practices of an Eastern Cape vehicle manufacturer
- Authors: Botha, Christo Johannes
- Date: 2006
- Subjects: Production management , Automobile industry and trade -- South Africa -- Eastern Cape , Industrial procurement
- Language: English
- Type: Thesis , Masters , MBA
- Identifier: vital:8558 , http://hdl.handle.net/10948/480 , Production management , Automobile industry and trade -- South Africa -- Eastern Cape , Industrial procurement
- Description: The world automotive industry has evolved through different manufacturing methodologies over many decades. It originated from craft production, but was transformed to mass production by Henry Ford in response to increased market demand. The methodology developed by Henry Ford made it possible to produce quality vehicles in large numbers and at affordable cost to the general public. However, it cannot deliver a great variety of products to the marketplace. Mass production was overtaken by a new automotive manufacturing methodology developed in Japan after World War II. The methodology, commonly referred to as lean production, yields consistently high quality products at even lower costs, whilst being able to deliver a variety of products to the consumer. The effectiveness of the lean production methodology hinges upon the strength and closeness of the relationships that exist between the assembler and its suppliers. Different models have been developed over time to describe the relationships between automotive assemblers and their suppliers. The lean supply model is generally accepted as an effective way of describing the relationships that exist between an automotive assembler and its first tier suppliers in a lean manufacturing environment. The research study aims at gaining an improved understanding of the relationships that exist between a selected Eastern Cape automotive assembler and its first tier suppliers. The effect of its supplier support practices towards lean manufacturing implementation amongst its first tier suppliers is evaluated. For the selected assembler it is found that the effect of its supplier support practices on lean manufacturing implementation amongst its first tier suppliers is limited by a non-uniform approach followed towards the supplier base. It is shown that opportunities for improvement exist for the selected assembler to develop closer relationships with its first tier suppliers to increase its global competitiveness.
- Full Text:
- Date Issued: 2006
- Authors: Botha, Christo Johannes
- Date: 2006
- Subjects: Production management , Automobile industry and trade -- South Africa -- Eastern Cape , Industrial procurement
- Language: English
- Type: Thesis , Masters , MBA
- Identifier: vital:8558 , http://hdl.handle.net/10948/480 , Production management , Automobile industry and trade -- South Africa -- Eastern Cape , Industrial procurement
- Description: The world automotive industry has evolved through different manufacturing methodologies over many decades. It originated from craft production, but was transformed to mass production by Henry Ford in response to increased market demand. The methodology developed by Henry Ford made it possible to produce quality vehicles in large numbers and at affordable cost to the general public. However, it cannot deliver a great variety of products to the marketplace. Mass production was overtaken by a new automotive manufacturing methodology developed in Japan after World War II. The methodology, commonly referred to as lean production, yields consistently high quality products at even lower costs, whilst being able to deliver a variety of products to the consumer. The effectiveness of the lean production methodology hinges upon the strength and closeness of the relationships that exist between the assembler and its suppliers. Different models have been developed over time to describe the relationships between automotive assemblers and their suppliers. The lean supply model is generally accepted as an effective way of describing the relationships that exist between an automotive assembler and its first tier suppliers in a lean manufacturing environment. The research study aims at gaining an improved understanding of the relationships that exist between a selected Eastern Cape automotive assembler and its first tier suppliers. The effect of its supplier support practices towards lean manufacturing implementation amongst its first tier suppliers is evaluated. For the selected assembler it is found that the effect of its supplier support practices on lean manufacturing implementation amongst its first tier suppliers is limited by a non-uniform approach followed towards the supplier base. It is shown that opportunities for improvement exist for the selected assembler to develop closer relationships with its first tier suppliers to increase its global competitiveness.
- Full Text:
- Date Issued: 2006
The management of the antecedents of absenteeism at a motor manufacturing company
- Authors: Mandleni, Oscar
- Date: 2011
- Subjects: Absenteeism (Labor) , Motor industry , Production management
- Language: English
- Type: Thesis , Masters , MBA
- Identifier: vital:8755 , http://hdl.handle.net/10948/d1011559 , Absenteeism (Labor) , Motor industry , Production management
- Description: Absenteeism is a complex set of behaviours masquerading as a unitary phenomenon. Absenteeism is a big problem in the motor manufacturing industry, especially, because of the number of processes that are labour intensive. Absenteeism is a multifaceted problem with many antecedents which make it challenging to resolve or contain. Financial impact is one of the consequences of absenteeism on a business, especially when one thinks that the primary objective of a firm in to make money. Absenteeism defeats these objectives through cost incurred for overtime to catch up production losses. Furthermore, in cases where replacement of personnel is necessary, this may include administrative costs related to the time human resource personnel spend looking for replacement employees or the time production management spends re-assigning employees. Absenteeism results in decreased productivity and may affect the quality of the product due to the increased workload and burden put on employees who are at work. Absenteeism is classified into scheduled and unscheduled absenteeism. Although some absenteeism is avoidable, it is important to understand that some absence is unavoidable. This is because people may fall ill, get injured or have unavoidable obligations which may lead to absenteeism. The purpose of this study was to identify the antecedents of absenteeism, with the assumption that once they are identified, they can be controlled, reduced or eliminated and the absenteeism rate thus reduced. The theoretical study focused on defining absenteeism, ascertaining the impact of absenteeism in the workplace, especially in an international organisation in the motor manufacturing industry and discussing the antecedents of absenteeism and strategies that can be used to manage these antecedents. The empirical study consisted of a survey, with a questionnaire as a data collecting tool. The process used to conduct the survey was to distribute the questionnaire among production employees in three operational units; namely Final Assembly, Paint Shop and Body Shop at a motor manufacturing company. Employees were approached, the purpose of the questionnaire explained and they were asked if they would be willing to complete the questionnaire. Employees who agreed to complete the questionnaire were briefed on the contents of the questionnaire and the completion process. The relationship between biographical variables and absenteeism was discussed. For the purpose of this study the following independent variables were discussed: age, marital status, gender, work area, length of service and number of dependents. The empirical study focused on the antecedents of absenteeism, and specifically job, organisational and personal factors, as well supervisors‟ attempts to manage absenteeism. The respondents indicated that they believed absenteeism was a problem in the study and that people stayed away for reasons other than genuine illness. It was recommended that absenteeism figures, such as the overall Gross Absence Rate (GAR) and Absence Frequency Rate for the organisation, and specific work areas and teams, are regularly communicated to employees and displayed prominently to emphasise the importance of attendance. Some suggestions were that: Supervisors should foster a genuinely respectful relationship between themselves and employees which will results in employees feeling obliged to be at work. The company should introduce a day care or crèche at work to allow female employees to bring their kids to work in the event they are unable to be looked after at home. Alcohol and drug abuse should not be seen as an external problem in the organisation but rather as something an organisation should get involved in to assist employee who might have a problem. The first step was to create a channel where employee can feel free to approach the company if they are in need of help. The study demonstrated that it was important to identify antecedents in order to address the real problems related to absenteeism.
- Full Text:
- Date Issued: 2011
- Authors: Mandleni, Oscar
- Date: 2011
- Subjects: Absenteeism (Labor) , Motor industry , Production management
- Language: English
- Type: Thesis , Masters , MBA
- Identifier: vital:8755 , http://hdl.handle.net/10948/d1011559 , Absenteeism (Labor) , Motor industry , Production management
- Description: Absenteeism is a complex set of behaviours masquerading as a unitary phenomenon. Absenteeism is a big problem in the motor manufacturing industry, especially, because of the number of processes that are labour intensive. Absenteeism is a multifaceted problem with many antecedents which make it challenging to resolve or contain. Financial impact is one of the consequences of absenteeism on a business, especially when one thinks that the primary objective of a firm in to make money. Absenteeism defeats these objectives through cost incurred for overtime to catch up production losses. Furthermore, in cases where replacement of personnel is necessary, this may include administrative costs related to the time human resource personnel spend looking for replacement employees or the time production management spends re-assigning employees. Absenteeism results in decreased productivity and may affect the quality of the product due to the increased workload and burden put on employees who are at work. Absenteeism is classified into scheduled and unscheduled absenteeism. Although some absenteeism is avoidable, it is important to understand that some absence is unavoidable. This is because people may fall ill, get injured or have unavoidable obligations which may lead to absenteeism. The purpose of this study was to identify the antecedents of absenteeism, with the assumption that once they are identified, they can be controlled, reduced or eliminated and the absenteeism rate thus reduced. The theoretical study focused on defining absenteeism, ascertaining the impact of absenteeism in the workplace, especially in an international organisation in the motor manufacturing industry and discussing the antecedents of absenteeism and strategies that can be used to manage these antecedents. The empirical study consisted of a survey, with a questionnaire as a data collecting tool. The process used to conduct the survey was to distribute the questionnaire among production employees in three operational units; namely Final Assembly, Paint Shop and Body Shop at a motor manufacturing company. Employees were approached, the purpose of the questionnaire explained and they were asked if they would be willing to complete the questionnaire. Employees who agreed to complete the questionnaire were briefed on the contents of the questionnaire and the completion process. The relationship between biographical variables and absenteeism was discussed. For the purpose of this study the following independent variables were discussed: age, marital status, gender, work area, length of service and number of dependents. The empirical study focused on the antecedents of absenteeism, and specifically job, organisational and personal factors, as well supervisors‟ attempts to manage absenteeism. The respondents indicated that they believed absenteeism was a problem in the study and that people stayed away for reasons other than genuine illness. It was recommended that absenteeism figures, such as the overall Gross Absence Rate (GAR) and Absence Frequency Rate for the organisation, and specific work areas and teams, are regularly communicated to employees and displayed prominently to emphasise the importance of attendance. Some suggestions were that: Supervisors should foster a genuinely respectful relationship between themselves and employees which will results in employees feeling obliged to be at work. The company should introduce a day care or crèche at work to allow female employees to bring their kids to work in the event they are unable to be looked after at home. Alcohol and drug abuse should not be seen as an external problem in the organisation but rather as something an organisation should get involved in to assist employee who might have a problem. The first step was to create a channel where employee can feel free to approach the company if they are in need of help. The study demonstrated that it was important to identify antecedents in order to address the real problems related to absenteeism.
- Full Text:
- Date Issued: 2011
An assessment of the supplier development practices at Volkswagen of South Africa
- Authors: Erasmus, Bradley Quentin
- Date: 2006
- Subjects: Volkswagen of South Africa (Firm) , Production management , Business logistics -- Management , Motor vehicle industry -- South Africa
- Language: English
- Type: Thesis , Masters , MBA
- Identifier: vital:8555 , http://hdl.handle.net/10948/500 , Volkswagen of South Africa (Firm) , Production management , Business logistics -- Management , Motor vehicle industry -- South Africa
- Description: The underlying objective of the research is to assess the nature of the supplier training at Volkswagen of South Africa (VWSA). To achieve this objective, a theoretical study was conducted to establish what literature reveals to be the most important theory of supply chain management as well as supplier development geared towards lean manufacturing. The information obtained in the literature study was analysed to solve the main problem namely, an assessment of the nature of the supplier training at Volkswagen of South Africa (VWSA). The research was divided into two questionnaires: The first questionnaire is targeted at the suppliers. This questionnaire has two sections namely section A, the biographical data and section B attempts to determine the quality systems and manufacturing requirements. It further attempts to gauge training support and needs as compared to other OEM’s. The second questionnaire is targeted at the Supplier Development Manager. The aim of this questionnaire is to establish what the current training offerings are, the source of what VWSA teachers and the awareness of the Toyota Training College.
- Full Text:
- Date Issued: 2006
- Authors: Erasmus, Bradley Quentin
- Date: 2006
- Subjects: Volkswagen of South Africa (Firm) , Production management , Business logistics -- Management , Motor vehicle industry -- South Africa
- Language: English
- Type: Thesis , Masters , MBA
- Identifier: vital:8555 , http://hdl.handle.net/10948/500 , Volkswagen of South Africa (Firm) , Production management , Business logistics -- Management , Motor vehicle industry -- South Africa
- Description: The underlying objective of the research is to assess the nature of the supplier training at Volkswagen of South Africa (VWSA). To achieve this objective, a theoretical study was conducted to establish what literature reveals to be the most important theory of supply chain management as well as supplier development geared towards lean manufacturing. The information obtained in the literature study was analysed to solve the main problem namely, an assessment of the nature of the supplier training at Volkswagen of South Africa (VWSA). The research was divided into two questionnaires: The first questionnaire is targeted at the suppliers. This questionnaire has two sections namely section A, the biographical data and section B attempts to determine the quality systems and manufacturing requirements. It further attempts to gauge training support and needs as compared to other OEM’s. The second questionnaire is targeted at the Supplier Development Manager. The aim of this questionnaire is to establish what the current training offerings are, the source of what VWSA teachers and the awareness of the Toyota Training College.
- Full Text:
- Date Issued: 2006
The strategic implementation of continuous improvement tools within manufacturing plants of the Eastern Cape
- Authors: Spence, Mark George
- Date: 2006
- Subjects: Automobile supplies industry -- South Africa -- Eastern Cape , Production management
- Language: English
- Type: Thesis , Masters , MBA
- Identifier: vital:8752 , http://hdl.handle.net/10948/611 , Automobile supplies industry -- South Africa -- Eastern Cape , Production management
- Description: Continuous improvement has long been considered a key business strategy to the success of any business that needs to be competitive and survive in a world that is continually evolving, particularly with the increased focus on meeting cost and quality targets that are set by a far more knowledgeable customer. Unfortunately, many organisations invest countless hours of their key personnel's time on training without creating a clear vision and consolidated strategic plan as to how continuous improvement will be driven in the business. Marginal elements of success are obtained, but the harnessing of these skills, as well as the true synergy that could be realized, are watered down due to the silos in which many of the activities are performed. Within the context of this dissertation, a conceptual approach to the strategic implementation of continuous improvement tools within the organization will be sought in order to enhance all facets of the business and not only the traditional arenas of the manufacturing disciplines. Murray and Roberts Foundries Group is embarking on the integration of current and new continuous improvement tools that form part of its continued improvement drive. This research was conducted with other organisations and will help shed light on Murray and Roberts Foundries Group’s way forward in the implementation of these tools to ensure long-term sustainable success. The intent of this dissertation is therefore to offer a comprehensive set of recommendations for Murray and Roberts Foundries Group’s top management in terms of its strategic implementation and the successful application of Lean manufacturing tools and techniques. In addition, areas and directions for further research are identified.
- Full Text:
- Date Issued: 2006
- Authors: Spence, Mark George
- Date: 2006
- Subjects: Automobile supplies industry -- South Africa -- Eastern Cape , Production management
- Language: English
- Type: Thesis , Masters , MBA
- Identifier: vital:8752 , http://hdl.handle.net/10948/611 , Automobile supplies industry -- South Africa -- Eastern Cape , Production management
- Description: Continuous improvement has long been considered a key business strategy to the success of any business that needs to be competitive and survive in a world that is continually evolving, particularly with the increased focus on meeting cost and quality targets that are set by a far more knowledgeable customer. Unfortunately, many organisations invest countless hours of their key personnel's time on training without creating a clear vision and consolidated strategic plan as to how continuous improvement will be driven in the business. Marginal elements of success are obtained, but the harnessing of these skills, as well as the true synergy that could be realized, are watered down due to the silos in which many of the activities are performed. Within the context of this dissertation, a conceptual approach to the strategic implementation of continuous improvement tools within the organization will be sought in order to enhance all facets of the business and not only the traditional arenas of the manufacturing disciplines. Murray and Roberts Foundries Group is embarking on the integration of current and new continuous improvement tools that form part of its continued improvement drive. This research was conducted with other organisations and will help shed light on Murray and Roberts Foundries Group’s way forward in the implementation of these tools to ensure long-term sustainable success. The intent of this dissertation is therefore to offer a comprehensive set of recommendations for Murray and Roberts Foundries Group’s top management in terms of its strategic implementation and the successful application of Lean manufacturing tools and techniques. In addition, areas and directions for further research are identified.
- Full Text:
- Date Issued: 2006
Implementing lean manufacturing to improve production efficiency in the manufacturing operations at the Aspen General facility
- Authors: Jozaffe, Lyndon Brian
- Date: 2006
- Subjects: Production management , Industrial efficiency
- Language: English
- Type: Thesis , Masters , MBA
- Identifier: vital:8557 , http://hdl.handle.net/10948/529 , Production management , Industrial efficiency
- Description: South African producers are constantly facing competition from foreign organisations in their domestic markets. The adverse effects of this competition stem, in part, from the low levels of productivity which characterise South African industry and which is well documented by the National Productivity Institute of South Africa. The concept of continuous improvement offers a proven methodology for increasing the effectiveness and efficiency of production processes. Given the situation that faces South African producers, it would seem appropriate to investigate how the concept of continuous improvement can be applied to a specific South African manufacturing organisation, like the Aspen Pharmacare General Facility, in order to improve its effectiveness and efficiency.
- Full Text:
- Date Issued: 2006
- Authors: Jozaffe, Lyndon Brian
- Date: 2006
- Subjects: Production management , Industrial efficiency
- Language: English
- Type: Thesis , Masters , MBA
- Identifier: vital:8557 , http://hdl.handle.net/10948/529 , Production management , Industrial efficiency
- Description: South African producers are constantly facing competition from foreign organisations in their domestic markets. The adverse effects of this competition stem, in part, from the low levels of productivity which characterise South African industry and which is well documented by the National Productivity Institute of South Africa. The concept of continuous improvement offers a proven methodology for increasing the effectiveness and efficiency of production processes. Given the situation that faces South African producers, it would seem appropriate to investigate how the concept of continuous improvement can be applied to a specific South African manufacturing organisation, like the Aspen Pharmacare General Facility, in order to improve its effectiveness and efficiency.
- Full Text:
- Date Issued: 2006
Assessment of the status of lean implementation at selected South African Revenue Service branch offices
- Authors: Samela, Thandile
- Date: 2011
- Subjects: Lean manufacturing -- Evaluation , Production management
- Language: English
- Type: Thesis , Masters , MBA
- Identifier: http://hdl.handle.net/10948/8702 , vital:26422
- Description: Governments around the world want to deliver better education, better health care, better pensions and better transportation services. They know that impatient electorates want to see change, and fast. But, the funds required to meet such expectations are enormous, particularly in the many developed economies where populations are aging and the public sector's productivity has not kept pace with that of the private sector. The need to get value for money from governments at all levels is therefore under the spotlight as never before. However, cost-cutting programmes that seek savings of 1 to 3% per year will not be sufficient and, in some cases, may even weaken the quality of service (Bhatia & Drew, 2006). One of the key innovative means to improve productivity, and do more with less, is through the implementation of lean initiatives. The purpose of this study is to conduct an 'Assessment of the status of lean implementation at selected SARS (South African Revenue Service) branch offices'. Literature review was conducted to investigate the origins of lean and how the service industry tapped from this philosophy, which was initially developed for the manufacturing sector. The lean philosophy has now been widely adopted in various service industries, from government agencies such as the South African Revenue Service to financial institutions such as ABSA bank, including the healthcare industry. The findings of the research indicated that even though the organisation has made a strategic decision to implement lean, this has not been entirely successful as there is a lack of understanding of lean among managers and team leaders. There are some pockets of excellence though. The researcher recommends that a comprehensive road map be developed to guide the organisation into a sustainable lean implementation.
- Full Text:
- Date Issued: 2011
- Authors: Samela, Thandile
- Date: 2011
- Subjects: Lean manufacturing -- Evaluation , Production management
- Language: English
- Type: Thesis , Masters , MBA
- Identifier: http://hdl.handle.net/10948/8702 , vital:26422
- Description: Governments around the world want to deliver better education, better health care, better pensions and better transportation services. They know that impatient electorates want to see change, and fast. But, the funds required to meet such expectations are enormous, particularly in the many developed economies where populations are aging and the public sector's productivity has not kept pace with that of the private sector. The need to get value for money from governments at all levels is therefore under the spotlight as never before. However, cost-cutting programmes that seek savings of 1 to 3% per year will not be sufficient and, in some cases, may even weaken the quality of service (Bhatia & Drew, 2006). One of the key innovative means to improve productivity, and do more with less, is through the implementation of lean initiatives. The purpose of this study is to conduct an 'Assessment of the status of lean implementation at selected SARS (South African Revenue Service) branch offices'. Literature review was conducted to investigate the origins of lean and how the service industry tapped from this philosophy, which was initially developed for the manufacturing sector. The lean philosophy has now been widely adopted in various service industries, from government agencies such as the South African Revenue Service to financial institutions such as ABSA bank, including the healthcare industry. The findings of the research indicated that even though the organisation has made a strategic decision to implement lean, this has not been entirely successful as there is a lack of understanding of lean among managers and team leaders. There are some pockets of excellence though. The researcher recommends that a comprehensive road map be developed to guide the organisation into a sustainable lean implementation.
- Full Text:
- Date Issued: 2011
Investigating the impact of supply chain technologies within automative supplier clusters
- Authors: Schultz, Lance Craig
- Date: 2013
- Subjects: Business logistics -- Technological innovations , Inventory control , Production management , Automobile industry and trade -- South Africa
- Language: English
- Type: Thesis , Masters , MBA
- Identifier: vital:8918 , http://hdl.handle.net/10948/d1021093
- Description: Organisations are constantly expected to be more competitive while working in an environment in which time and cost are limited, thereby preventing such organisations from taking the time required to be responsive. The supply chain provides a critical linkage between various organisations which should seek collective opportunities to improve performance. It is, therefore, important that organisations understand that conventional knowledge and methods will not serve unless there is a concerted focus on improvement of organisational performance toward fulfilling increased expectations, not just maintaining that which is comfortable. A more sustainable approach may be the introduction of supply chain best practice. An optimal supply chain is one that continuously strives to reduce unnecessary cost and eliminate waste, thereby increasing the percentage of time that may be devoted to value-adding activities. Supply chain technology principles were assessed and the application thereof, sought to understand its efficiency and effectiveness. This study was intended to identify supply chain cost dimensions with a focus on the optimal use of supply chain technology. Within the current supply chain context, the use of Information and Communication Technology (ICT) was explored to identify opportunities. A supply chain audit tool (SCAT) was developed which had proven to be an effective tool to analyse it’s logistics functions. Implementation of remedial tools through the SCAT could result in a leaner, cost optimal and more value-adding process. The result of conducting individual organisational improvements is expected to result in an overall improvement in the total supply chain. These supply chain cost drivers were rooted in cost, quality, safety and product performance. Recommendations on further improvements were also offered.
- Full Text:
- Date Issued: 2013
- Authors: Schultz, Lance Craig
- Date: 2013
- Subjects: Business logistics -- Technological innovations , Inventory control , Production management , Automobile industry and trade -- South Africa
- Language: English
- Type: Thesis , Masters , MBA
- Identifier: vital:8918 , http://hdl.handle.net/10948/d1021093
- Description: Organisations are constantly expected to be more competitive while working in an environment in which time and cost are limited, thereby preventing such organisations from taking the time required to be responsive. The supply chain provides a critical linkage between various organisations which should seek collective opportunities to improve performance. It is, therefore, important that organisations understand that conventional knowledge and methods will not serve unless there is a concerted focus on improvement of organisational performance toward fulfilling increased expectations, not just maintaining that which is comfortable. A more sustainable approach may be the introduction of supply chain best practice. An optimal supply chain is one that continuously strives to reduce unnecessary cost and eliminate waste, thereby increasing the percentage of time that may be devoted to value-adding activities. Supply chain technology principles were assessed and the application thereof, sought to understand its efficiency and effectiveness. This study was intended to identify supply chain cost dimensions with a focus on the optimal use of supply chain technology. Within the current supply chain context, the use of Information and Communication Technology (ICT) was explored to identify opportunities. A supply chain audit tool (SCAT) was developed which had proven to be an effective tool to analyse it’s logistics functions. Implementation of remedial tools through the SCAT could result in a leaner, cost optimal and more value-adding process. The result of conducting individual organisational improvements is expected to result in an overall improvement in the total supply chain. These supply chain cost drivers were rooted in cost, quality, safety and product performance. Recommendations on further improvements were also offered.
- Full Text:
- Date Issued: 2013
The effectiveness of lean principles in South African manufacturing companies
- Authors: Erasmus, Daveril Lionel
- Date: 2020
- Subjects: Lean manufacturing , Production management
- Language: English
- Type: Thesis , Masters , MBA
- Identifier: http://hdl.handle.net/10948/50546 , vital:42218
- Description: The Lean approach is a widely discussed and applied manufacturing philosophy in a variety of industries across the globe (Gupta & Jain, 2013), with only a few within the manufacturing industry able to truly say they have not heard of Lean (Melton, 2005). Lean is defined as a philosophy that applies specific tools and methods in a consistent, disciplined and systematic manner to eliminate waste and improve operational effectiveness, where the necessary processes are performed in a sequence in order to achieve the desired results. The effectiveness of Lean has been well established, with organisations from all over the world and from different industries having proved that Lean principles are well founded. However, despite its effectiveness the implementation of Lean manufacturing into an organisation is not an easy task due to various barriers opposing the effective implementation of Lean principles. The study was carried out in the South African (SA) Tank manufacturing industry. The study aimed at to establish a framework for successful implementation of Lean principles. The organisation where research took place, Welfit Oddy, is located in Perseverance, Port Elizabeth (PE) in SA. It is a manufacturing company which specializes in the design, manufacture and sale of tank containers and bulk liquid shipping containers and transport containers used to transport and deliver various goods such as milk, gas, chemicals, oil, petrol and liquid chemicals to customers and end users. The organisation has served this global industry for more than 25 years and is considered by many to be one of the biggest and best manufacturers of intermodal ISO tank containers in the world. Tank containers, also referred to as ISO tanks, intermodal tanks or IMO portable tanks, are designed for intermodal transportation by road, rail, air, and ship (Erera, Morales & Savelsbergh, 2005). In this study, emphasis will be placed on the issues that need to be addressed for the effective implementation of the Lean Manufacturing philosophy within the organisation.
- Full Text:
- Date Issued: 2020
- Authors: Erasmus, Daveril Lionel
- Date: 2020
- Subjects: Lean manufacturing , Production management
- Language: English
- Type: Thesis , Masters , MBA
- Identifier: http://hdl.handle.net/10948/50546 , vital:42218
- Description: The Lean approach is a widely discussed and applied manufacturing philosophy in a variety of industries across the globe (Gupta & Jain, 2013), with only a few within the manufacturing industry able to truly say they have not heard of Lean (Melton, 2005). Lean is defined as a philosophy that applies specific tools and methods in a consistent, disciplined and systematic manner to eliminate waste and improve operational effectiveness, where the necessary processes are performed in a sequence in order to achieve the desired results. The effectiveness of Lean has been well established, with organisations from all over the world and from different industries having proved that Lean principles are well founded. However, despite its effectiveness the implementation of Lean manufacturing into an organisation is not an easy task due to various barriers opposing the effective implementation of Lean principles. The study was carried out in the South African (SA) Tank manufacturing industry. The study aimed at to establish a framework for successful implementation of Lean principles. The organisation where research took place, Welfit Oddy, is located in Perseverance, Port Elizabeth (PE) in SA. It is a manufacturing company which specializes in the design, manufacture and sale of tank containers and bulk liquid shipping containers and transport containers used to transport and deliver various goods such as milk, gas, chemicals, oil, petrol and liquid chemicals to customers and end users. The organisation has served this global industry for more than 25 years and is considered by many to be one of the biggest and best manufacturers of intermodal ISO tank containers in the world. Tank containers, also referred to as ISO tanks, intermodal tanks or IMO portable tanks, are designed for intermodal transportation by road, rail, air, and ship (Erera, Morales & Savelsbergh, 2005). In this study, emphasis will be placed on the issues that need to be addressed for the effective implementation of the Lean Manufacturing philosophy within the organisation.
- Full Text:
- Date Issued: 2020
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
An analysis of the barriers that inhibit sustainable implementation of LEAN
- Authors: Sidinile, Ayanda
- Date: 2014
- Subjects: Lean manufacturing , Production management
- Language: English
- Type: Thesis , Masters , MBA
- Identifier: vital:8934 , http://hdl.handle.net/10948/d1021192
- Description: With global advances in technology, many organizations are finding it difficult and quite challenging to do business as usual. Japanese companies are on top of the world economy, while many Western companies are struggling to find ways to compete with them (Womack, et al., 1990). The Japanese secret weapon “Lean Production” is no longer a secret; more and more western companies are now learning and adopting Lean techniques to remain relevant and competitive. Lean management is a consistent philosophy and a set of practices that must be maintained over time in order to see the gains (Losonci & Demeter, 2013). Lean is not a quick fix to reduce costs, but a continuous improvement journey that will transform an organization into a cost efficient value-driven system. Lean is still a fairly new phenomenon in South Africa, particularly in the Eastern Cape. The road towards the lean implementation is viewed by many as a challenging and yet rewarding journey. South African organizations are following the trend of implementing lean in order to eliminate waste, improve quality, speed, customer satisfaction and thereby increasing profits. It is however still a long journey towards achieving total perfection. The main challenge facing South African organizations is the ability to sustain the lean improvements over a longer period. This study will focus on identifying and analyzing the main barriers that inhibit many successful organizations from sustaining lean improvement efforts.
- Full Text:
- Date Issued: 2014
- Authors: Sidinile, Ayanda
- Date: 2014
- Subjects: Lean manufacturing , Production management
- Language: English
- Type: Thesis , Masters , MBA
- Identifier: vital:8934 , http://hdl.handle.net/10948/d1021192
- Description: With global advances in technology, many organizations are finding it difficult and quite challenging to do business as usual. Japanese companies are on top of the world economy, while many Western companies are struggling to find ways to compete with them (Womack, et al., 1990). The Japanese secret weapon “Lean Production” is no longer a secret; more and more western companies are now learning and adopting Lean techniques to remain relevant and competitive. Lean management is a consistent philosophy and a set of practices that must be maintained over time in order to see the gains (Losonci & Demeter, 2013). Lean is not a quick fix to reduce costs, but a continuous improvement journey that will transform an organization into a cost efficient value-driven system. Lean is still a fairly new phenomenon in South Africa, particularly in the Eastern Cape. The road towards the lean implementation is viewed by many as a challenging and yet rewarding journey. South African organizations are following the trend of implementing lean in order to eliminate waste, improve quality, speed, customer satisfaction and thereby increasing profits. It is however still a long journey towards achieving total perfection. The main challenge facing South African organizations is the ability to sustain the lean improvements over a longer period. This study will focus on identifying and analyzing the main barriers that inhibit many successful organizations from sustaining lean improvement efforts.
- Full Text:
- Date Issued: 2014
A causal analysis to investigate low production efficiency in the tyre manufacturing industry in South Africa
- Authors: Bruinders, Bramwill Bertram
- Date: 2021-04
- Subjects: Industrial efficiency , Production management , Lean manufacturing -- South Africa
- Language: English
- Type: Master's theses , text
- Identifier: http://hdl.handle.net/10948/50977 , vital:43177
- Description: The evolution of tyre manufacturing in South Africa went back to the early 1930s and matured technologically, becoming automated in the 1960s. The tyre industry in South Africa is worth approximately R30bn per annum and is one of the major supporting industries for domestic vehicle manufacturers. The local industry manufactures only 11 million tyres but can manufacture 18 million tyres per annum. The tyre industry thus plays a crucial role in South Africa’s economic development. Consumers are opting to buy cheaper imported tyres even though tyres are essential purchases. Therefore, the major tyre manufacturers must compete against an estimated 200 importers of various brands, most from China and Japan. The excess local capacity and increasing volume of imports put the local tyre manufacturers under severe pressure to grow their market share, reduce operational cost and achieve economies of scale. The study’s general objective was to conduct a root cause analysis of South African tyre manufacturers’ underlying issues resulting in low production efficiencies. This study used critical manufacturing principles such as traceability, knowledge of lean principles, lean implementation challenges, Total Quality Management, organisational buy-in, waste and rework and maintenance planning that constitute tools of lean practices. These principles provided an opportunity to adopt efficient manufacturing practices in tyre manufacturing companies and help organisations identify improvement areas. A questionnaire was developed and distributed electronically to 93 respondents employed in the tyre manufacturing industry in South Africa. The study addressed product traceability, investigated the quality measures in place, and examined the influence of the workforce’s attitude and morale on productivity, and determined management’s influence on decision-making. The key findings indicated that traceability, lean implementation challenges and organisational buy-in played a significant role in improving production efficiency. Recommendations were made to management to ensure that they lead by example and enhance these key constructs to foster their growth. , Thesis (MBA) -- Faculty of Business and Economic Sciences, Business Administration , 2021
- Full Text:
- Date Issued: 2021-04
- Authors: Bruinders, Bramwill Bertram
- Date: 2021-04
- Subjects: Industrial efficiency , Production management , Lean manufacturing -- South Africa
- Language: English
- Type: Master's theses , text
- Identifier: http://hdl.handle.net/10948/50977 , vital:43177
- Description: The evolution of tyre manufacturing in South Africa went back to the early 1930s and matured technologically, becoming automated in the 1960s. The tyre industry in South Africa is worth approximately R30bn per annum and is one of the major supporting industries for domestic vehicle manufacturers. The local industry manufactures only 11 million tyres but can manufacture 18 million tyres per annum. The tyre industry thus plays a crucial role in South Africa’s economic development. Consumers are opting to buy cheaper imported tyres even though tyres are essential purchases. Therefore, the major tyre manufacturers must compete against an estimated 200 importers of various brands, most from China and Japan. The excess local capacity and increasing volume of imports put the local tyre manufacturers under severe pressure to grow their market share, reduce operational cost and achieve economies of scale. The study’s general objective was to conduct a root cause analysis of South African tyre manufacturers’ underlying issues resulting in low production efficiencies. This study used critical manufacturing principles such as traceability, knowledge of lean principles, lean implementation challenges, Total Quality Management, organisational buy-in, waste and rework and maintenance planning that constitute tools of lean practices. These principles provided an opportunity to adopt efficient manufacturing practices in tyre manufacturing companies and help organisations identify improvement areas. A questionnaire was developed and distributed electronically to 93 respondents employed in the tyre manufacturing industry in South Africa. The study addressed product traceability, investigated the quality measures in place, and examined the influence of the workforce’s attitude and morale on productivity, and determined management’s influence on decision-making. The key findings indicated that traceability, lean implementation challenges and organisational buy-in played a significant role in improving production efficiency. Recommendations were made to management to ensure that they lead by example and enhance these key constructs to foster their growth. , Thesis (MBA) -- Faculty of Business and Economic Sciences, Business Administration , 2021
- Full Text:
- Date Issued: 2021-04
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
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