This thesis examines and develops a proposed manufacturing system methodology and quality control for the design, planning, scheduling and implementation of the Thermiculite 866 high volume manufacturing line, through the use of Lean Manufacturing, Total Quality Management and Change Management principles. The concept under investigation extends to the analysis of flow production benefits and restrictions considering specific characteristics of the product. A novel factory design methodology is proposed to achieve required production volumes and cost effective implementation. Furthermore, high product quality levels are warranted by developing a Strategic Alignment of Quality Function Deployment which brings commercial awareness to the early stages in the product/process development, and reduces the time to market it whilst promoting long-term solutions. The process and the layout design are supported by a proposed Batch/Flow Comparative Matrix. As a result, the proposed factory design methodologies and management of change introduced in the organization led to a successful production system design as well as controlled implementation according to stakeholders requirements. The design and partial implementation of the Thermiculite 866 production line illustrates the effectiveness of the methodology proposed in this thesis to manage and design the equipment and quality for the future Thermiculite production line.

This thesis examines and develops a proposed manufacturing system methodology and quality control for the design, planning, scheduling and implementation of the Thermiculite 866 high volume manufacturing line, through the use of Lean Manufacturing, Total Quality Management and Change Management principles. The concept under investigation extends to the analysis of flow production benefits and restrictions considering specific characteristics of the product. A novel factory design methodology is proposed to achieve required production volumes and cost effective implementation. Furthermore, high product quality levels are warranted by developing a Strategic Alignment of Quality Function Deployment which brings commercial awareness to the early stages in the product/process development, and reduces the time to market it whilst promoting long-term solutions. The process and the layout design are supported by a proposed Batch/Flow Comparative Matrix. As a result, the proposed factory design methodologies and management of change introduced in the organization led to a successful production system design as well as controlled implementation according to stakeholders requirements. The design and partial implementation of the Thermiculite 866 production line illustrates the effectiveness of the methodology proposed in this thesis to manage and design the equipment and quality for the future Thermiculite production line. / Technology Strategy Board for the Knowledge Transfer Partnership (KTP)