Submitted in fulfilment of the requirements of the Degree of Master of Technology: Quality, Durban University of Technology, 2011 / The manufacturing sector, considered to be an important industry in any country, is often plagued with a significant degree of competition due to global marketing. In order to cope with this challenge, organisations attempt to improve their manufacturing operations by using different tools and techniques to reduce costs while remaining profitable. This study investigated the existing lean production system of an automotive manufacturing organisation in Durban. The objective of the study was to identify the strengths and weaknesses of the current lean manufacturing process in an attempt to improve quality and productivity. An empirical study was conducted, using a survey questionnaire with an assessment score ranking to gather and evaluate employees’ responses pertaining to lean application in the production environment. The quantitative method of research was adopted. The results of the study showed evidence of misalignment and inconsistencies for lean adoption in the organisation. There were significant relationships established between departments and job positions. The analysis demonstrated that operators within production showed the highest sentiment of disagreement for certain lean principles. The validity of the operators’ responses was significant as operators are the frontline of all processes and were in the best position to rank the extent of lean adoption. Several important findings on the implications of lean activities that affect manufacturing performance were revealed. The study concluded that a significant gap exists between the actual adoption of lean principles on the shop floor to those that are documented. It is recommended that organisations develop structured follow up procedures in order to have more control of the production system and thus ensure sustainability. Future research should focus at incorporating better and more efficient lean assessment tools to identify gaps in the production system and to replicate this study to track other South African organisations that claim to manufacture lean.

Submitted in partial fulfilment of the requirements for the Degree of Masters in Business Administration, Durban Institute of Technology, 2008. / The aim of this research is to analyze the introduction of lean manufacturing in a selected South African organization viz. Smiths Manufacturing. The research, together with its conclusions, may identify problematic areas which, once addressed, will improve the implementation in other areas and identify the benefits, if any, of lean manufacturing. Three research objectives exist and two methods of research were used to solve the research questions. The first and second research objectives (i.e. to analyze the manner in which lean manufacturing was introduced in Smiths Manufacturing and its benefit on the company's competitive position and future existence) were analyzed qualitatively with the aid of personal interviews. The third research objective (i.e. to determine the financial benefit of lean manufacturing introduction on the respective assembly line) was analyzed quantitatively. This research revealed three pertinent findings: Firstly, Smiths Manufacturing has adhered to eight of Liker's 13 Step Implementation Procedure with two areas of non-conformance being identified and insufficient information present to comment on the remaining three steps. Secondly, improvements in the manufacturing process have enabled the company to be more price competitive. Areas of improvement were in labour, raw materials and finished goods. These improvements will assist in ensuring the company's future existence. Thirdly, there has been a substantial amount of savings by the introduction of lean manufacturing. This research has identified that communication involving lean manufacturing is vital to introducing a system into a company. This communication enables people at all levels to understand the roll out procedure and the corresponding actions of the company. In addition, the research revealed that the / M

Submitted in fulfilment for the requirements of the degree of Master of Technology: Business Administration in the Faculty of Management Sciences at the Durban University of Technology, 2009. / Competition is increasing as trading borders continue to widen in this global marketplace. As a result, South African organisations need to improve their efficiencies. The primary objective of the study was to examine the effectiveness of the Lean Enterprise Strategy (LES) at improving business efficiency, in the electrical pre-payment industry in KZN. Several underlying objectives which support the primary objective were examined and realtionships established. Two forms of empirical studies, observation and questionaire based, were used. These studies provided substantive findings which were analysed and interpreted. A positive relationship between the LES and business efficiency were established and the various underlying objectives addressed. Communication was found to be inadequate and highlighted. It was also found that there is a substantial delay in return on investments; therefore, sustainability should be targeted and the LES should have a continual re-cycling mechanism, which allows it not only to be sustainable, but also renewable.

On a daily basis organizations strive to achieve maximum output with minimum input for greater levels of efficiency and profitability. However, in our dynamic modern world and economy the variables have changed dramatically and the time when business was simply about the ‘bottom line’ and all else was subordinate to the objective of profit, has come and gone. In the contemporary world of business today the variables are much broader and more dynamic, as people are no longer just employees, and suppliers are no longer people whose payment should be delayed for as long as possible. In addition, the environment is no longer to be plundered at all costs. Today Lean as an all-encompassing management philosophy with its emphasis on adding value, is more relevant in business than at any other point in business history. At a time when the global economy is facing some of its greatest challenges, it is ultimately business and its networks that, through effective management, can restore the global economy and provide livelihoods to millions of people. The Lean management philosophy is about constantly searching for the best possible way of doing things and eliminating waste in pursuit of value. If Lean is in pursuit of eliminating waste and turning it into value, and the customer, irrespective of required product, is in constant pursuit of finding value, then Lean is surely the management philosophy that can deliver the greatest level of customer satisfaction. This means satisfied customers returning to an organization for repeat sales as long as they perceive that the value they derive meets their expectations.

In this intensely competitive environment of the global economy, the survival of even the most established manufacturers depends on their ability to continuously improve quality whilst reducing costs. The resulting productivity of producing more with less is the only key to market leadership and sustainable competitive advantage. Changing production methods from mass-production to Lean Manufacturing has become the essential practise for successful manufacturers (Rogers and Sim, 2009). The purpose of this study is to investigate what factors negate the adoption and implementation of Lean Manufacturing as a means to gain competitive advantage. The focus was on companies that have participated in the AIDC Tirisano cluster programme. The study investigated what effect Organisational Culture, Leadership Behaviours, Employee Involvement and Strategy Integration have on Lean Manufacturing adoption and implementation. This study applied the mixed methodologies of qualitative and quantitative approaches using methodological triangulation. A cross sectional analytical survey approach in a descriptive case study was undertaken. The findings from the questions and the interviews from the respondents who participated in the survey indicated that the practices in some companies enable the successful adoption and implementation of Lean Manufacturing whilst in some others the practices will negatively affect the adoption and implementation. The study concludes by stating that South African automotive component manufacturers are under immense pressure to improve quality and reduce costs. Initiatives like Lean Manufacturing should be undertaken in order to bring about these improvements. But this improvement comes about by changing the current way of doing things. Companies need to undertake a total approach when implementing Lean as part of the business strategy and this must be driven by management as leaders and a team culture that involves all employees needs to be present.

This time of great change, of shifting paradigms, provides a great platform for universities to rethink their processes (Duderstadt, 2000). Thanks to the pioneering success of the Toyota Motor Company for the invention of lean manufacturing. This operating system has been implemented in many manufacturing companies, with recent successes reported in the service industry. With its focus on quality improvement, cost reduction, efficiency and excellency, lean has been recognised as one of the mechanisms for process improvement and organisational change. In terms of fully embracing lean principles, the service industry still lags far behind the manufacturing, with institutions of higher learning still quite far. Numerous authors have confirmed that institutions of learning are not an easy environment to change. Universities are still characterised by bureaucratic systems based on conventional processes that are not necessarily relevant to today‘s world. The old saying that change in the universities occur one grave at a time is not farfetched (Hines and Lethbridge, 2008 and Paul and Brindley, 1996). The impact of globalisation on business education and how to respond to this phenomenon is a challenge. This necessitates a need for more streamlined and efficient organisations; hence lean has been promoted as a strategy to achieve competitive advantage (Simmons and Masson, 2003). The research study aims to identify areas where lean principles can be implemented to improve the NMMU MBA application process. Semi-structured interviews were conducted with employees directly involved in the process in order to understand it better. The results of the respondents were reported in a process chart diagram and spaghetti diagram. The interviews also revealed five themes that emerged during the analysis of responses. These themes formed the basis for development of recommendations in Chapter 6 of the study.

In following a lean transformation specifically for discrete manufacturing, how and why will the organisational structure be affected? How will the employees deal with this profound change? Lean theory and literature propose that organisations should be restructured according to the value stream of the organisation; what does this imply and how can it be accomplished? The purpose of this study was to determine, from a new perspective, guidelines and theory that could indicate how and why organisational structures and behaviours might change with lean transformation. Two discrete manufacturing organisations in South Africa were purposively sampled for this purpose. A conceptual framework was used at the outset that indicated constructs for the independent lean variables and the dependent organisational structure and behaviour variables. Using a mixed methodology case study and quantitative multiple linear regression approach, hypotheses and propositions for the research were developed. Multiple linear regression was used to test the hypotheses, and case study methodology was applied to analyse and test the qualitative data. Findings confirmed the hypotheses and propositions that a flat structure consisting of business units that support manufacturing cells achieves effective lean transformations in discrete manufacturing organisations. The research revealed the components of an effective lean structure as open constructive leadership, an effective lean champions unit and business units that support linked manufacturing cells. These are led by cell leaders who cultivate supportive behaviours through cross-functional teamwork and through self-directed work teams who run manufacturing cells or flow support functions. / Business Management / D.B.L.

In following a lean transformation specifically for discrete manufacturing, how and why will the organisational structure be affected? How will the employees deal with this profound change? Lean theory and literature propose that organisations should be restructured according to the value stream of the organisation; what does this imply and how can it be accomplished? The purpose of this study was to determine, from a new perspective, guidelines and theory that could indicate how and why organisational structures and behaviours might change with lean transformation. Two discrete manufacturing organisations in South Africa were purposively sampled for this purpose. A conceptual framework was used at the outset that indicated constructs for the independent lean variables and the dependent organisational structure and behaviour variables. Using a mixed methodology case study and quantitative multiple linear regression approach, hypotheses and propositions for the research were developed. Multiple linear regression was used to test the hypotheses, and case study methodology was applied to analyse and test the qualitative data. Findings confirmed the hypotheses and propositions that a flat structure consisting of business units that support manufacturing cells achieves effective lean transformations in discrete manufacturing organisations. The research revealed the components of an effective lean structure as open constructive leadership, an effective lean champions unit and business units that support linked manufacturing cells. These are led by cell leaders who cultivate supportive behaviours through cross-functional teamwork and through self-directed work teams who run manufacturing cells or flow support functions. / Business Management / D.B.L.

The world has become more competitive, complex and unpredictable, and this process is continuing. Evolution is taking place resulting in organisations being pushed by strategies and pulled by increasingly assertive customers who demand more accountability and responsiveness (Kartte, 2010). In order to remain competitive in this changing world, many organisations, even financial institutions have adopted Lean principles in order to eliminate waste, reduce cost and streamline everyday processes (Spear, 2012). There have however been a number of challenges that have prevented financial institutions from implementing Lean principles successfully. The primary objective of this study is to improve the effectiveness of Lean principles within a specific financial institution. More specifically, this study will identify the effectiveness of successfully implementing Lean principles at a financial institution by investigating the influence of employee knowledge, understanding and skills, communication, motivation and ownership from management, organisational culture and the impact of trade unions in organisations as mentioned in the problem statement above. Convenience sampling was used to select a sample of sixty eight (68) employees within the specific financial institution. The sample was stratified to include senior managers, managers, team leaders and lower level employees. Questionnaires were distributed personally to the focus groups from the above categories.

This study determined whether local manufacturers of light vehicles in South Africa employ supply chain best practices and strategies. The research design employed was a combination of exploratory and descriptive research design using qualitative and quantitative approaches based on a survey of light vehicle manufacturers in South Africa. A face-to–face, semi-structured interview questionnaire was used, based on purposive sampling. Descriptive statistics using SPSS software were used for the data analysis and interpretation. The findings of the study revealed that across the supply chain, best practices were implemented to a large extent by all manufacturers. Light vehicle manufacturers in South Africa, however face supply chain challenges, which include technological, infrastructural, cost, market/service and production/skills challenges. The most important supply chain performance indicator that contributes to optimisation of performance is quality, followed by final product delivery reliability, and then cost and supplier reliability. All the manufacturers followed a lean strategy for their inbound supply chain and some had a lean supply chain strategy for their outbound supply chain. A number of them also had an agile supply chain strategy in the outbound supply chain which suggests a leagile supply chain strategy. It was also found that in some instances there was a mismatch between strategies and practices in the area of product characteristics, manufacturing characteristics and the decision drivers of supply chain. One of the conclusions of the study was that local manufacturers of light vehicles do not always make decisions and implement practices in line with their chosen supply chain strategies. The study concluded by developing a framework for determining supply chain best practices in line with a chosen strategy that could guide supply chain managers (in locally manufactured light vehicles) in the automotive in South Africa in their decision making. / Business Management / D. Com. (Business Management)