Thesis (MScEng (Industrial Engineering))--University of Stellenbosch, 2006. / The Theory of Constraints is a management philosophy based on the underlying assumption that only a few constraining factors limit the throughput of the entire system. Drum-Buffer-Rope is the production logistical solution of the Theory of Constraints. It is the implementation of Constraints Management on the manufacturing shop floor, to manage physical resource constraints. Drum-Buffer-Rope was designed with the purpose of increasing Throughput, while simultaneously decreasing Inventory, and minimising Operating Expense. It aims to accomplish these goals by focusing on simplifying and therefore reducing variability in the production process, and ultimately protecting order due dates against disruptions. The dynamic conditions under which typical job shops operate can make Constraints Management of the resource constraints a cumbersome task. By following a “What If” approach to the scheduling process, the scheduler can play an interactive role in developing practical shop floor schedules. In this way the scheduler can see the results of his/her ideas on the shop floor situation quickly as immediate feedback is provided. The Drum-Buffer-Rope methodology only finite schedules certain points in the manufacturing process therefore scheduling calculations can be performed quickly if done in software. This makes it possible for the scheduler to analyse various scenarios in a short period of time and allowing the development of near optimal shop floor schedules by following a “What If” approach to scheduling. In this project, new developments in the field of Drum-Buffer-Rope were investigated, and the newly developed Simplified Drum-Buffer-Rope methodology was researched. The methodologies were incorporated in a fully developed software package that uses Drum-Buffer- Rope or Simplified Drum-Buffer-Rope to marry the intrinsic knowledge of the shop-floor worker with modern day computer technology to create production schedules that can be released to the shop floor. Schedules are created rapidly enough by the software to enable the scheduler to follow a “What If” approach to create near optimal shop floor schedules. The developed software was used with live data from a South African job shop to illustrate the “What If” approach to Simplified Drum-Buffer-Rope scheduling. The results show that throughput can be increased and operating expense decreased, therefore increasing bottom line results, by analysing various scenarios.

Thesis (MScEng)--Stellenbosch University, 2012. / ENGLISH ABSTRACT: Capitalising on South Africa’s innovation resource through entrepreneurship in the creative industries. In light of the current global challenges as well as local needs and opportunities, there is a need for improved utilisation of South Africa’s innovation resource. Due to designers possessing creativity and the ability to innovate, it is proposed that an increase in the quality and quantity of entrepreneurship activity in the creative sectors will have notable impacts on the sustainability, competitiveness and value of South Africa’s economic activity. It is argued that designers and creative individuals inherently possess a number of entrepreneurial traits and that design education promotes the development of many entrepreneurial behaviours. Thus, it is necessary to offset and maximise these skills with the requisite businessrelated cognitions, attributes and abilities. For this reason, this study looks at the contextual characteristics and needs of small businesses operating in South African design sectors. The objective is to provide relevant and practical suggestions for improving ‘effective’ entrepreneurial activity in the design industries. The current state of entrepreneurship education in a representative sample of South African entrepreneurship courses is analysed. The outcome of this process is used as a base-line in consulting a number of experts in the South African small- and medium-sized enterprise (SME) sector, in order to ascertain the context-specific ‘success factors’ for small businesses in South Africa. Empirical data is then gathered regarding the current state of entrepreneurship and small business content in design education in South Africa. The results of all these processes are analysed in conjunction with the empirical results regarding the individually perceived abilities and attitudes of designers currently operating small businesses in South Africa. The outcome of this analysis is a framework describing the important elements (and relationships between elements) necessary in the development of effective entrepreneurial ability. / AFRIKAANSE OPSOMMING: Benutting van Suid-Afrika se innovasie hulpbron deur middel van entrepreneurskap in die kreatiewe bedrywe. In lig van die huidige wêreldwye uitdagings, insluitend die plaaslike behoeftes en geleenthede, is daar ‘n noodsaaklikheid vir die beter benutting van Suid-Afrika se innovasie-hulpbron. As gevolg van die feit dat ontwerpers oor kreatiwiteit en die vermoë om te innoveer beskik, word daar voorgestel dat ‘n verhoging in die gehalte en hoeveelheid entrepreneuriese aktiwiteite in die kreatiewe sektore ‘n beduidende impak op die volhoubaarheid, mededingendheid en waarde toevoeging van Suid-Afrika se ekonomiese aktiwiteite sal hê. Daar word geredeneer dat ontwerpers en kreatiewe individue oor ‘n bepaalde aantal intrinsieke entrepreneuriese eienskappe beskik en verder dat ‘n aantal entrepreneuriese gedragspatrone deur ontwerp onderwys ontwikkel en bevorder kan word. Dit is daarom nodig om hierdie vaardighede met die vereiste sake beginsels, eienskappe en vermoëns te versterk en optimeer. Om hierdie rede ondersoek hierdie studie die kontekstuele eienskappe en behoeftes van klein sake-ondernemings in die Suid-Afrikaanse ontwerp sektore. Die doel is om toepaslike en praktiese voorstelle vir die verbetering van ‘effektiewe’ entrepreneuriese aktiwiteite in die ontwerp nywerhede te voorsien. Die huidige stand van entrepreneurskap-onderwys is bepaal deur ‘n verteenwoordigende steekproef van die Suid-Afrikaanse entrepreneurskap kursusse te ontleed. Die uitkoms van hierdie proses word gebruik as ‘n basis-lyn in die raadpleging van ‘n aantal deskundiges in die Suid- Afrikaanse klein sake-sektor, ten einde die konteks-spesifieke ‘sukses faktore’ vir klein ondernemings in Suid-Afrika vas te stel. Empiriese data word dan versamel met betrekking tot die huidige stand van die entrepreneurskap en kleinsake inhoud wat in die ontwerp onderwys van Suid-Afrika vervat word. Die resultate van al hierdie prosesse is ontleed tesame met die empiriese resultate wat verkry is ten opsigte van die vermoëns en houdings wat gekoppel word aan ontwerpers wat tans werksaam is in die klein ondernemings in Suid-Afrika. Die uitkoms van hierdie analise poog om ‘n raamwerk daar te stel vir die beskrywing van die belangrikste elemente (en verhoudings tussen elemente) wat benodig word in die ontwikkeling van effektiewe entrepreneuriese vermoëns.

Thesis (MScEng)--Stellenbosch University, 2012. / ENGLISH ABSTRACT: Sliding wear is a complicated form of wear involving different factors. The factors affecting the process are the mechanical properties of the materials, sliding distance, sliding speed, and normal force applied to the contact. An experimental study was conducted to assess the performance of Ti6Al4V in self-mated and various counterface material contact couples subjected to linear reciprocating dry sliding motion. The normal force was varied for all the experiments to understand the effect it had on specific couples. Sliding wear experiments were also conducted on cemented carbides coupled with Ti6Al4V. In certain applications carbide coatings are used and could possibly come into contact with Ti6Al4V. Cemented carbides used in the study were manufactured through spark plasma sintering and liquid phase sintering. An in depth study was conducted to assess the spark plasma sintered materials and compare these to those manufactured through liquid phase sintering. The experimental study revealed that an increase in normal force, in sliding experiments, led to an increase in friction and wear volume loss of the Ti6Al4V pin. In addition the experiments found that Ti6Al4V was prone to adhesion and surface oxidation. / AFRIKAANSE OPSOMMING: Glyslytasie is 'n gekompliseerde slytasievorm wat verskillende faktore behels.Die faktore wat die proses beïnvloed is die meganiese eienskappe van die materiale,gly-afstand,glyspoed en normale druk(krag) wat op die kontakoppervlakte toegepas word. 'n Eksperimentele studie om die werksverrigting van Ti6Al4V in verenigde en verskeie teenwerkende materiaal kontakpare wat onderwerp is aan lineêre omgekeerde droë gly-aksie te assesseer is uitgevoer.Die normale krag vir al die eksperimente om die effek wat dit op die spesifieke pare gehad het te verstaan is gevarieer. Glyslytasie-eksperimente is ook op gesementeerde karbiedes wat met Ti6Al4V gekoppel is,uitgevoer. In sekere toepassings is karbiedlae gebruik en kon moontlik met Ti6Al4V in kontak gekom het. Gesementeerde karbiedes wat in die studie gebruik is, is deur vonkplasmasinter en vloeibare fase-sinter vervaardig. 'n Indieptestudie is ook uitgevoer om die vonkplasmasintermateriale en dié materiale wat deur vloeibare fasesinter vervaardig is te vergelyk. Die eksperimentele studie het getoon dat 'n toename in normale krag in glyeksperimente gelei het tot 'n toename in wrywing en slytasievolumeverlies van die Ti6Al4V pin. Bykomend tot die eksperimente is gevind dat Ti6Al4V geneig was tot adhesie en oppervlakteoksidasie.

Thesis (MScEng (Industrial Engineering))--University of Stellenbosch, 2007. / This project was initiated to develop a new and novel approach to address complex sequencing problems, in particular, an alternative method was developed to find solutions to the sequential ordering problem. The sequential ordering problem is concerned with the arrangement of a number of elements in a sequence that respects a number of precedence constraints and results in the lowest overall cost. A precedence constraint requires that some element will occur before another in the solution sequence, and the cost of a solution is determined by summing the independent individual costs that are incurred when progressing from one specific element in the solution sequence to another. Instances of this problem are regularly found in the practice of industrial engineering in problems such as the routing of a delivery vehicle, the scheduling of jobs on a machine and the preparation of project plans with limited resources. The sequential ordering problem is known to be complex in the sense that as the size of problem instances increases, the best-known time required to find a guaranteed optimal solution increases exponentially.

Thesis (MScEng (Industrial Engineering))--University of Stellenbosch, 2005. / The LOMOLD process is a new plastic moulding process being researched at the University of Stellenbosch. The process essentially combines injection moulding and compression moulding. Molten plastic is forced into the mould cavity using a plunger. This plunger then forms part of the cavity wall. The plunger face must therefore follow the geometry of the part. Rapid Tooling evolved from Rapid Prototyping. There are two categories of Rapid Tooling: indirect and direct rapid tools. Indirect rapid tools are manufactured by using a master pattern to form the mould cavity. The accuracy of the mould cavity depends heavily on the accuracy of the master pattern. The master pattern is usually produced using Rapid Prototyping technology. Direct rapid tools use Rapid Prototyping technology to build the mould through and additive, layer by layer process or a subtractive process. This research investigates the use of Rapid Tools for the LOMOLD process. Aluminium Filled Epoxy Tooling (AFET) represents the indirect technology and CNC-machined tooling the direct technology. Both of these technologies are available at the University of Stellenbosch. Parts are manufactured on these tools using an experimental LOMOLD machine. These two technologies are compared in terms of part accuracy, tool lead time, tool cost and part cost. The research concluded that the only advantage the AFET has over the CNC-machined tool is a shorter manufacturing lead-time. In terms of tool cost, tool life, part geometric accuracy, part cost and cycle time the CNC tool is superior. Therefore the application of AFET is limited to small volume, prototype or pre-production runs for tool design confirmation, part functional testing and part appearance testing. It is also demonstrated that a cooling system on the AFET tool has no significant influence on the tool performance and should therefore, especially for production runs less than 150 parts, not be included in the tool to save on tool cost. Another conclusion is that the LOMOLD process is not consistent enough for a production process. This statement could be limited to the machine used for the research but to prove this statement wrong, the machine must be improved and more investigation is required.

Thesis (MScEng (Industrial Engineering))--University of Stellenbosch, 2007. / The supply of manufactured products depends on tool, die and mould (TDM) manufacturing. The TDM industry provides the machines, tools and equipment necessary to produce most manufactured components. The TDM industry is a high value-adding constituent in the supply of manufactured products by being at the heart of component manufacturing and by forming the backbone of the manufacturing sector. Unfortunately, the South African TDM industry experienced a steady economic decline during the last decade. This decline resulted in a negative effect on the domestic manufacturing industry. The South African government realised the evident need to restructure and develop the TDM industry. This research forms part of government incentives to increase global competitiveness of the South African TDM industry. The South African TDM industry lacks the capacity to supply in the local demand. This study determines shortfalls and the need for improvement by comparing the South African industry against its global counterparts. A benchmarking methodology is developed to identify improvement plans for individual tool rooms and for the industry as a whole. Recommendations for the domestic industry are provided through conclusions drawn from the study. The benchmarking methodology can be applied to an industry or to an individual concern. A pilot implementation of the methodology was performed in three specific tool rooms. This thesis analysis the South African TDM industry in its entirety and provides recommendations to improve competitiveness.

Thesis (MSc)--University of Stellenbosch, 2007. / ENGLISH ABSTRACT: This study was initiated in October 2004 when Vizier Systems (Pty) Ltd approached the Department of Industrial Engineering at the University of Stellenbosch with a concept. They proposed that a fruit packing line be represented as a series of unit operations and suggested that the concept could be used to create a generic model that can be used to represent any packing line. After further discussions with Vizier about the concept and their reasons for requiring a generic model, a formal client requirement was formulated. It was decided that the generic modelling concept had to be tested in the citrus industry. Modelling theory was investigated and a generic modelling methodology was formulated by adapting an existing modelling methodology. The first few steps of the developed methodology led to industry data being gathered and several role-players in the citrus export industry being visited. An analysis of the data enabled the development of the necessary techniques to do distribution estimation and forecasting of the system input, which is fruit. The various processes were grouped into generic groups and detailed capacity calculations were developed for each process. The fruit parameter estimation techniques and capacity calculations were integrated into a five step modelling procedure. Once the generic model was set up to represent a specific packing line, the modelling procedure provided optimum flow rates, equipment setups and personnel allocations for defined production runs. The modelling procedure was then translated into a computer model. This allowed a complete capacity analysis of a packing line by incrementally varying the characteristics of the fruit input. The developed generic model was validated by comparing its predictions to the results of two production runs at an existing packing line. It was found that the generic model is able to adequately represent the packing line and that the fruit inputs and outputs can be accurately estimated. The concept proposed by Vizier, that a packing line can be generically modelled as a series of unit operations, was shown to be valid. / AFRIKAANSE OPSOMMING: Hierdie studie is in Oktober 2004 geïnisieer toe Vizier Systems (Pty) Ltd die Departement van Bedryfsingenieurswese aan die Universiteit van Stellenbosch met ’n konsep genader het. Hulle het aan die hand gedoen dat ’n vrugtepaklyn voorgestel kan word as ’n reeks eenheidsprosesse en dat die konsep gebruik kan word om ’n generiese model te skep om enige vrugtepaklyn te verteenwoordig. Na verdere samesprekings met Vizier oor die konsep en hul redes vir die noodsaaklikheid van ’n generiese model, is ’n formele kliëntebehoefte geformuleer. Daar is besluit dat die generiese modelleringskonsep in die sitrusbedryf getoets gaan word. Modelleringsteorie is ondersoek en ’n generiese modelleringsmetodologie is geformuleer deur ’n bestaande modelleringsmetodologie aan te pas. Die stappe van die ontwikkelde metodologie het gelei tot die insameling van data vanuit die industrie en verskeie rolspelers in die sitrus-uitvoerindustrie is besoek. ’n Analise van die data het die ontwikkeling van die tegnieke moontlik gemaak wat nodig was om verspreidingsberamings en voorspelling van die stelselinset – die vrugte – te doen. Die onderskeie prosesse is gegroepeer in generiese groepe en gedetailleerde kapasiteitsberekeninge is vir elke proses ontwikkel. Die vrugparameter beramingstegnieke en kapasiteitsberekeninge is geïntegreer in ’n vyf-stapmodelleringsprosedure. Nadat die generiese model opgestel is om ’n spesifieke paklyn voor te stel, het die modelleringsprosedure optimum vloeitempo’s, toerustingopstellings en personeeltoedelings vir die spesifieke produksielopie gegee. Die modelleringsprosedure is toe herlei tot ’n rekenaarmodel. Dit het ’n volledige kapasiteitsanalise van die paklyn moontlik gemaak, deur die eienskappe van die vruginset inkrementeel te varieer. Die ontwikkelde generiese model is gestaaf deur sy voorspellings te vergelyk met die resultate van twee produksielopies van ’n bestaande paklyn. Daar is bevind dat die generiese model in staat is om die paklyn voldoende voor te stel en dat dit die vruginsette en -uitsette akkuraat kon beraam. Die geldigheid van die konsep wat voorgestel is deur Vizier, naamlik dat ’n paklyn generies gemodelleer kan word as ’n reeks eenheidsprosesse, is bevestig.

Thesis (MScEng (Industrial Engineering))--University of Stellenbosch, 2009. / South Africa has a two-fold agricultural sector consisting of large-scale, industrialised, commercial farmers, as well as small-scale, resource poor subsistence farmers. One of the aspirations of the post-1994 South African Government is to rectify the imbalances in South African agriculture, where less than 20% of the farmers produce more than 80 % of total national agricultural products. In an attempt to improve supply from previously disadvantaged farmers, a land redistribution programme was launched with the goal of transferring 30% of total agricultural land to black farmers by 2014. However, farmers that are beneficiaries of the land transformation and redistribution programme often struggle to sustain the previous levels of productivity of the land. This is due to inexperience in macro-agriculture as well as a lack of resources. In such cases the beneficiaries revert back to subsistence type farming on previously productive and successful commercial farms. This phenomenon can have a devastating effect on the country’s food security, Gross Domestic Product, unemployment rates and the farmer’s prosperity and development opportunities. By reverting to small-scale farming, access to formal marketing chains is also restricted because of the economies of scales required to sustain a competitive supply to these markets. Urgent strategies are therefore required to improve the competitiveness of farmers who farm on a small scale due to restricted resources and inexperience. In this regard two proven theories to analyse industries for improved competitiveness exist, namely value chain analysis and clustering. Both are investigated in this study in order to determine their suitability for application in the emerging farming sector of South Africa. Value chain analysis has been widely applied to production and manufacturing industries (including agricultural production and agri-food manufacturing) to scrutinise production processes. Valuable insight into an industry’s strong and weak points can be gained by studying various factors. These include the inputs required for the manufacturing of the final product, the steps or processes required in the chain of events, the value added in each step, the contributors in the chain, as well as the linkages between the contributors. Knowledge is also gained regarding chain and process optimisation potential for improved competitiveness. The clustering of small firms to improve their ability to compete in formal markets has received a significant amount of academic interest over the past 100 years. In this regard it is important to determine the factors that influence competitiveness, and to develop strategies to improve the potential of small-scale manufacturing firms to compete with larger scale enterprises. The clustering or grouping of small firms to co-operate with each other and to compete against larger firms – as opposed to competing against each other – has resulted in improved competitiveness for many small firms across the world. A number of common key success factors for improving the competitiveness of smallscale, resource poor farmers are identified in this study through the investigation of a host of case studies. The results from these case studies also provide adequate evidence that the analysis and upgrading of value chains, as well as the promotion of collective action by small farmers, are key components for improving competitiveness and market access. This study focuses on the development of a framework to guide the development of strategies for improving competitiveness amongst small-scale, resource poor farming industries, including a production cost analysis sheet to calculate the competitiveness of farmers in this sub-sector. The Framework is also evaluated for its functionality by looking at the implementation thereof amongst a group of emerging farmers in the Western Cape.

Thesis (MScEng (Industrial Engineering))--University of Stellenbosch, 2007. / Product Lifecycle Management (PLM) is defined as the business activity of managing a company's products across the product lifecycle. Product Data Management (PDM) systems are the primary system component of PLM. The focus of this research is on the implementation of PDM software within the context of PLM. Fifty percent of all PLM projects fail. Failure implies no bottom-line benefit is achieved with the implementation. The main reason for failure is not the technology but the implementation approach used. The research question addressed by this thesis is: How can it be ensured that bottom-line benefit is achieved with the implementation of PLM technology? The Necessary but not Sufficient (N&S) solution is based on Theory of Constraints principles and was developed to help achieve significant bottom-line benefit with the implementation of new technology. This is accomplished through focusing on the removal of limitations (something that prevents the company from better achievement of its goal of increasing profit) as well as addressing the necessary organisational changes (the N&S solution refers to the changing of customs, habits, policies, procedures, metrics and behaviour). This research applies the N&S solution to the PLM software environment in order to address the research question. The outcome of the project is an implementation methodology that will ensure bottom-line benefit will be achieved with the implementation of PLM software. This implementation methodology was applied to a practical case study from an analysis point of view and was validated with cause and effect logic.

Thesis (MScEng (Industrial Engineering))--University of Stellenbosch, 2008. / Call centres form an increasingly important part of the modern day business environment and perform an important role in the strategic and operational aspects of organisations. Call centres have emerged and developed to provide efficient and cost effective communication channels between organisations and their customers. Call centres are often the largest or only channel used to access customers or for customers to access organisations. Early call centres were seen as cost centres and operated in a similar manner, often resulting in poor and unsatisfactory performance. Modern call centres are being approached in a different way. They are aligned with the strategic objectives of the organisation and are seen as performance centres and revenue drivers. Modern call centres are dynamic and complex organisations, both technologically and operationally. Performance objectives are often conflicting and controlling parameters have to be finely balanced in a volatile environment. It is therefore imperative to utilise call centres effectively and efficiently. This can only be achieved by a structured and scientific operations research based approach. The research was initiated by the requirement of a call centre design and implementation as part of a larger business process reengineering project. The thesis provides an overview of the call centre environment and operational aspects. A structured call centre design model is reviewed and two aspects namely workforce management and performance management are found to form the core of the design and operations activities. The call centre design model is then integrated with the proposed workforce management and performance management models. These models are developed using scientific operations research approach. The structured modelling approach is then used to guide the design, operation, and optimisation of the call centre of the case study. The structured and scientific operations research based approach proved to be of great significance when confronted with the dynamic and complex call centre environment. Through using the structured approach the design, operation, and optimisation activities could be conducted successfully and performance objectives were reached.