This dissertation discusses the application of additive manufacturing technologies for production of a large-scale rapid prototyping machine, which will be used to produce moulds for prototype composite turbine blades for the emerging renewables energy industry within the Eastern Cape region in South Africa. The conceptualization and design of three complete printer builds resulted in the amalgamation of a final system, following stringent theoretical design, simulation, and feasibility analysis. Following the initial product design cycle stage, construction and performance testing of a large-scale additive manufacturing platform were performed. In-depth statistical analysis of the mechatronic system was undertaken, particularly related to print-head locational accuracy, repeatability, and effects of parameter variation on printer performance. The machine was analysed to assess feasibility for use in the mould-making industry with accuracy and repeatability metrics of 0.121 mm and 0.156 mm rivalling those produced by some of the more accurate fused deposition modellers commercially available. The research data gathered serves to confirm that rapid prototyping is a good alternative manufacturing method for wind turbine blade plug and mould production.

A partir dos estudos realizados por Shingo (1996), Ohno (1997), e Womack e Jones (1998), este estudo buscou identificar quais os elementos que interferem no desempenho da manufatura enxuta da empresa Ognibene, nas unidades do Brasil e da Itália, na visão dos funcionários e dos gestores. A partir deste objetivo, buscou-se relacionar os elementos da manufatura enxuta, seu grau de importância, o grau de entendimento dos gestores e funcionários quanto aos cinco princípios fundamentais da produção enxuta, e realizar proposições para complementar sua atual aplicação. A metodologia da pesquisa aplicada para o alcance dos objetivos foi a pesquisa quantitativa descritiva, com caráter exploratório, operacionalizada através de um estudo de caso. Os resultados obtidos evidenciam a identificação dos elementos da manufatura enxuta aplicados na empresa Ognibene, e as conclusões demonstram que os objetivos deste estudo foram atingidos, contribuindo para uma melhor compreensão da manufatura enxuta e dos ganhos que podem ser o btidos com sua aplicação. / Submitted by Ana Guimarães Pereira (agpereir@ucs.br) on 2015-08-06T18:29:07Z No. of bitstreams: 1 Dissertacao Evandro Lazzarotto.pdf: 2542061 bytes, checksum: 819a59c2c337199f36eb17e6b16cbf4c (MD5) / Made available in DSpace on 2015-08-06T18:29:07Z (GMT). No. of bitstreams: 1 Dissertacao Evandro Lazzarotto.pdf: 2542061 bytes, checksum: 819a59c2c337199f36eb17e6b16cbf4c (MD5) / From the studies performed by Shingo (1996), Ohno (1997), and Womack & Jones (1998), this essay aimed to identify the factors that influence the performance of the lean manufacturing at Ognibene Company, in the view of its employees and management staff, in the Brazilian and Italian locations. Based on this target, this study tried to relate the elements of lean manufacturing, its importance level, the understanding level of managers and employees about the five principles of lean manufacturing, and make proposals to complement its current application. To achieve the objectives, this research applied the descriptive quantitative methodology, with exploratory character, operationalized through a case study. The obtained results show the identification of the lean manufacturing elements applied at Ognibene Company, and the conclusion demonstrates that the objectives of this essay were achieved, contributing for a better comprehension of the lean manufacturing and the gains that can be acquired with its application.

A partir dos estudos realizados por Shingo (1996), Ohno (1997), e Womack e Jones (1998), este estudo buscou identificar quais os elementos que interferem no desempenho da manufatura enxuta da empresa Ognibene, nas unidades do Brasil e da Itália, na visão dos funcionários e dos gestores. A partir deste objetivo, buscou-se relacionar os elementos da manufatura enxuta, seu grau de importância, o grau de entendimento dos gestores e funcionários quanto aos cinco princípios fundamentais da produção enxuta, e realizar proposições para complementar sua atual aplicação. A metodologia da pesquisa aplicada para o alcance dos objetivos foi a pesquisa quantitativa descritiva, com caráter exploratório, operacionalizada através de um estudo de caso. Os resultados obtidos evidenciam a identificação dos elementos da manufatura enxuta aplicados na empresa Ognibene, e as conclusões demonstram que os objetivos deste estudo foram atingidos, contribuindo para uma melhor compreensão da manufatura enxuta e dos ganhos que podem ser o btidos com sua aplicação. / From the studies performed by Shingo (1996), Ohno (1997), and Womack & Jones (1998), this essay aimed to identify the factors that influence the performance of the lean manufacturing at Ognibene Company, in the view of its employees and management staff, in the Brazilian and Italian locations. Based on this target, this study tried to relate the elements of lean manufacturing, its importance level, the understanding level of managers and employees about the five principles of lean manufacturing, and make proposals to complement its current application. To achieve the objectives, this research applied the descriptive quantitative methodology, with exploratory character, operationalized through a case study. The obtained results show the identification of the lean manufacturing elements applied at Ognibene Company, and the conclusion demonstrates that the objectives of this essay were achieved, contributing for a better comprehension of the lean manufacturing and the gains that can be acquired with its application.

O conceito fundamental da economia do conhecimento diz respeito à troca de produtos e serviços baseados no conhecimento. Nesse contexto e numa perspectiva de mercado, o conhecimento pode ser considerado um recurso cujo valor advém de mecanismos tradicionais de mercado, como é o caso da propriedade intelectual, ou na perspectiva do conhecimento como um bem público, aberto e circulante e que pode, portanto, ser livremente compartilhado em mercados de conhecimento. Essa abordagem assume que produtos ou serviços baseados no conhecimento estão disponíveis para distribuição, que alguém quer usá-los, e que o foco do mercado é conectar os dois. O objetivo dessa tese é propor um modelo de desenvolvimento baseado em conhecimento, a partir de mercados de conhecimento, para a geração de inovação aberta nas organizações tradicionais de manufatura. Nesse sentido, essa tese se desenvolve no contexto de mercados de conhecimento, e se apoia na teoria do Desenvolvimento Baseado em Conhecimento. O método utilizado foi composto de duas etapas: (1) Estudo exploratório qualitativo com organizações tradicionais de manufatura; (2) Método Delphi, com participação de especialistas em Desenvolvimento Baseado em Conhecimento de diferentes países. Os resultados obtidos fundamentaram a proposição de um modelo construído em uma perspectiva de processo de produção de conhecimento e fluxo de valor, no qual foram articulados os elementos habilitadores, entradas, direcionadores, catalisadores e saídas. A geração de novos conhecimentos torna o modelo cíclico e incremental. A inovação aberta apresenta-se como um catalisador, que ao formalizar a colaboração, potencializa as transferências de conhecimento, proporcionando a geração de novos conhecimentos. O estudo contribuiu para a teoria ao aproximar a visão de negócios tradicionais e baseados em conhecimento e a orientação para a informação; esclarecer a relação entre grau de abertura da inovação, complexidade do projeto e competências internas; reconhecer a importância das plataformas no contexto de mercados de conhecimento; entender o processo de produção de conhecimento como sendo cíclico e incremental, por meio da aprendizagem e da reputação; e, promover o avanço da pesquisa em DBC no contexto organizacional. O estudo evidenciou também o desequilíbrio existente entre as práticas de TI, gestão da informação e comportamento e valores das pessoas para o uso da informação; clarificou a importância dos capitais de conhecimento para as organizações tradicionais, no sentido de proporcionar diferenciação de mercado; posicionou a inovação aberta como um catalisador, no contexto da criação de novos produtos/serviços baseados em conhecimento; ressaltou a importância do desenvolvimento e adesão das organizações tradicionais a plataformas colaborativas que possam aproximar os atores em mercados de conhecimento; e, endereçou formas de reposicionar o capital financeiro como um meio, não como um fim, por meio do modelo de DBC desenvolvido. / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior, CAPES / The fundamental concept of the knowledge economy relates to the exchange of knowledgebased products and services. In this context and in a market perspective, knowledge can be considered as a resource whose value comes from traditional market mechanisms, such as intellectual property, or from the perspective of knowledge as a public, open and circulating good and that can be freely shared in knowledge markets. This approach assumes that knowledge-based products or services are available for distribution, that someone wants to use them, and that the focus of the market is connecting the two. The aim of this thesis is to propose a model of knowledge-based development, from knowledge markets, to the generation of open innovation in traditional manufacturing organizations. In this sense, this thesis develops in the context of knowledge markets, and it is based on the Knowledge Based Development theory. The method used was composed of two steps: (1) qualitative exploratory study with traditional manufacturing organizations; (2) Delphi Method, with the participation of knowledge-based development specialists from different countries. The results obtained were based on the proposition of a model built on a process of knowledge production and value flow perspectives, in which the enablers, inputs, drivers, catalysts and outputs elements were articulated. The generation of new knowledge makes the model cyclical and incremental. Open innovation is presented as a catalyst, which, by formalizing collaboration, enhances the transfer of knowledge, providing the generation of new knowledge. The study contributed to the theory by approaching traditional and knowledgebased business vision and information orientation; clarify the relationship between degree of innovation openness, project complexity and internal competencies; recognize the importance of platforms in the context of knowledge markets; understanding the process of knowledge production as being cyclical and incremental, through learning and reputation; and, promote the advancement of DBC research in the organizational context. The study also revealed theimbalance between IT practices, information management and behavior and people's values for the use of information; clarified the importance of knowledge capitals for traditional organizations in order to provide market differentiation; has positioned open innovation as a catalyst in the context of creating new knowledge-based products / services; emphasized the importance of the development and adhesion of the traditional organizations to collaborative platforms that can approach the actors in knowledge markets; and addressed ways of repositioning financial capital as a means, not as an end, through the developed DBC model.

O conceito de Empresas Virtuais vem sendo amplamente discutido no atual contexto de globalização dos mercados e da produção. Uma Empresa Virtual (EV) é uma rede temporária de entidades que se unem para explorar uma oportunidade de negócio, compartilhando competências, custos e acesso ao mercado. Apesar da EV ser composta por várias empresas diferentes, é fundamental gerenciar essa rede como se fosse uma única empresa. No entanto, para formação de EVs voltadas a produtos manufaturados existe uma lacuna na sua fase de operação: a carência de métodos adequados para executar o planejamento e controle da produção. O objetivo deste trabalho é propor um modelo de referência para o planejamento e controle da produção em EV, visando dar suporte a sua operação distribuída, porém de forma integrada. Esse modelo define um conjunto de atividades para o planejamento e controle da produção em EVs, as informações necessárias para realizá-las e a estrutura organizacional responsável pela execução das mesmas. Para elaborar o modelo, são determinadas as características de EVs e de sua gestão da produção, e considerados os processos envolvidos no ciclo de vida de uma EV. Por fim, um exemplo do planejamento e controle da produção em uma EV fictícia é elaborado para ilustrar a utilização do modelo proposto. / The concept of Virtual Enterprises has been widely discussed in the current context of market and production globalization. A Virtual Enterprise (VE) is a temporary enterprise network that joint themselves to exploit a business opportunity by sharing competences, costs and market share. Even though a VE is composed by different enterprises, it is fundamental to manage this network like a single company. However, while forming a VE for manufacturing sector, there is a gap in the operational phase: the lack of appropriated methods to execute the production planning and control. The goal of this work is to propose a reference model for production planning and control in VE, in order to support its distributed operation, but in an integrated way. This model defines a set of activities for the production planning and control in a VE, the required information to perform them and also the organizational model responsible for their execution. To elaborate the model, it was determined the features of VEs and its production management, and also considered the VE lifecycle processes. An example of production planning and control in a fictitious VE is elaborated to illustrate the proposed model utilization.

M.Tech. (Operations Management) / Please refer to full text to view abstract

M.Comm. / This study establishes an introductory management tool in the form of a computergenerated report card. The report card displays an overview of ~II pertinent key performance areas within an explosives production plant. The key performance areas cater for the planning, organising, staffing, reporting and controlling of explosives within an explosives production facility. The concept of the report card for the explosives production manager, makes use of the balanced scorecard as well as other key performance management tools to encourage management control, open communication and enhance performance drivers. The overall objective of the dissertation is to use certain assumptions that have become current in academic discussions of management control with particular relevance to aligning strategic control in order to establish what constituents may influence the production facilities' effectiveness, safety, efficiency and future focus areas for managers in the explosives production environment. There is nothing new about the basic notion of combining a number of performance measures in a compact description for a business operation. Recent developments have yielded useful approaches for management control within production companies. This research paper takes an avid search into the various communication tools, financial views, production flexibility, performance drivers, experience as well as development aspects that take place on a day-to-day basis within the explosives production facility. The essential indicators that constitute attention from management are outlined and drafted as a management tool that allows for the total comprehensive picture of the explosives production factory to be accurately reported and acted upon. This allows for more precise information upon which easier decision-making can take place.

D.Phil. / The new millennium brought its own pressures to bear on organisations insofar as competitiveness and profitability is concerned. Globalisation required businesses to become more competitive through the elimination of waste, reducing costs and improving general business processes. The improvement of business processes has been around since the early 1990’s, but due to a number of factors organisations were wary of change. The major reasons were that the methodologies that were available were abused when business processes were investigated for possible improvement. Organisations utilised the available methodologies to achieve cost savings in the most obvious place, staff reductions. Before the advent of globalisation it was sufficient, but after globalisation more is expected from organisations. The security exchanges place undue pressure on organisations to perform with higher profit expectations. Customers were demanding better and cheaper products from organisations. Shareholders had higher expectations for the monies invested in an organisation. A consequence of the downsizing of organisations was that the value added by organisations was shrinking. Employees, shareholders and customers felt cheated. Business leaders were questioning the existing methods in which production were undertaken. The management of large conglomerates, multinationals and even small business was yearning for improvements. In the global economy organisations were looking to expand their market share. Many achieved it through mergers or takeovers. The organisations that were taken over were in some instances not on the same standards of performance as the parent company. Quick results were required to assure a reasonable return on investment for the parent organisation. Business leaders and consultants ran out of ideas how to achieve the return on investment required. Many of the organisations returned to the tried and trusted methodologies of improvement. The researcher was requested by ASSA ABLOY Southern Africa to assist them in achieving lean status through the implementation of recognised improvement methodologies. iii The research of the methodologies of BPR, lean production, lean techniques, Quality management six-sigma and associated methodologies were undertaken. The purpose was to determine whether the theories remained valid in the 21st century. The reason was that some of the methodologies were developed during the 1900’s and were improved upon during the 1990’s. The main thrust of the study was the need for improvements where processes were neglected for a long period of time. In instances as described, a need for radical interventions becomes necessary. The methodology of BPR was investigated to establish the relevancy of the methodology in the global environment. Even though the methodology was developed in the 1990’s it was still an authoritative methodology. The methodology delivered the necessary radical improvements that can aid an organisation in becoming more competitive. The correct application of the methodology by an organisation can produce the desired results. The study of the methodology produced clear procedures that had to be followed for the success of an improvement project. The conclusion from the study of the literature was that the methodology could be applied to ASSA ABLOY Southern Africa. To achieve it certain modifications had to be made to the methodology. As the study progressed it became apparent that the methodology of BPR will be insufficient to achieve lean status. Therefore the methodology of lean production was studied in combination with BPR. The methodology of lean production demands that an organisation eliminate waste and reduce cost. The single most important source of waste and cost is the holding of inventory. The holding of excess inventory masks the real reasons why an organisation is not performing well. It is that the organisations processes are dysfunctional. Different classes of waste were identified during the research as well as the costs that are incurred as a result. Different strategies were identified to prevent the wastes and cost to occur or at least minimise it. The lean methodology identified a number of other methodologies that could be utilised to achieve lean status. The methodologies of Kaizen, Kanban, standardisation, small batch production and many others were identified. iv The methodologies focussed on inventory, capacity, facilities and labour. The conclusion was arrived at that it was an authoritative set of methodologies. Most of the methodologies originated from Japan. It became apparent that the management of quality was very important to be competitive. Inferior quality was major contributors towards waste and cost. A number of methodologies were investigated. In some instances the research postulated the fact that a combination of the methodologies studied was better suited to the achievement of lean status. The researcher applied the methodologies to the case study of ASSA ABLOY South Africa and spectacular improvements were achieved. Even though lean status was not achieved by the organisation during 2006 and 2007 they are well on their way to do so. The only prerequisite is that ASSA ABLOY Southern Africa remains true to the methodologies and apply them diligently.

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.

The Toyota manufacturing system, aptly referred to as Lean manufacturing, has received a reasonable appreciation and awareness over the past decade in South African industry. This production phenomenon constitutes an organizational culture that encourages world-class production success through the liberation of factory resources, while employees are empowered and encouraged to contribute ideas for the improvement of processes and products. However, despite lean awareness and the crucial role of employee participation in the suggestion of ideas in world-class organizations, the performance level of lean manufacturing in South African industry is largely devoid of the Kaizen suggestion tool, particularly in the automotive companies of the Eastern Cape. The aim of this research was to proffer appropriate recommendations, improved awareness, understanding and practice for the improvement of the Kaizen suggestion principle in the automotive companies of the Eastern Cape. The research primarily focused on the ‘management/employees’ paradigm within the organisational context. The methodology employed in the study included a thorough review of the relevant literature and a questionnaire, which was developed and administered to both the management and employees of the thirty automotive components suppliers in Eastern Cape. The target companies constituted the units of analyses and therefore provided the opportunity for a detailed investigation of the links between management and employees as well as a submission of ideas for operational and organisational processes as established in the literature review. Epistemologically, the research is objectivist and paradigmically, positivist. However, some qualitative aspects of the data were relevant to the study and, therefore, were used in a complementary manner. The case approach utilized mixed methods by applying a range of data collection techniques and evidence from multiple sources while the sampling technique was sequential, involving both purposive and stratified random sampling. The study reveals the apparent lack of a systematic mechanism for the practice and administration of the Kaizen suggestion tools in most Eastern Cape automotive companies. This demerit is found to have negatively affected maximum employee participation and involvement in organizational decision making within the Province. The study has established a basic level of awareness and understanding among employees / employers relations that the Kaizen suggestion scheme is a vital tool for delivering strategic objectives in the management of decision making and organizational growth. The study strongly advocates the inclusion of employee suggestion systems as part of the organizational process.