Lean philosophy is based on the continuous quest to improve the organisation’s processes by creating a culture and operating principles which eliminate all non value adding activities within organisation‘s processes. Manufacturing firms consider the adoption of the Lean tools as basic requirements for achieving World Class operational excellence or Best Practice. For some time, lean has been used by the manufacturing organizations. Most organizations understand that lean will help them survive global competition and stay in business. According to Hanna (2007:1), service industries, in general, are a long way behind manufacturing in terms of operations and improvements, and not all lean manufacturing ideas translate from the factory floor to office cubicle. The objective of this study is to investigate how lean manufacturing tools can be used to improve efficiency, customer service and enhance the embedding of a continuous improvement culture in the South African Revenue Services East London office Taxpayer Service business area. The activities that took place in the Taxpayer Service business area from 21 July 2008 until 31 October 2008 were observed. During the observation period, taxpayer services staff members were engaged formally, using surveys to assess their underlying mindset and behaviour as well as informally, using unstructured interviews to solicit more information on activities taking place and the reasoning behind certain actions. The movements of taxpayers who visited the branch office were monitored and the time it took for taxpayers to be assisted was measured as well as the time it took taxpayers to be assisted by a service agent or service consultant. To see if the available resources were used efficiently, the numbers of service channels available were compared to the number of service channels occupied. The results of the survey and observations are analysed and interpreted.

An increase in global competitiveness has forced manufacturing organisations to re – look at their facility from an output and quality standpoint. Leveraging a manufacturing operation into a competitive advantage must at all times support the organisation’s objectives. It is therefore vital that the operation reviews its strategy so that it fulfils the everchanging needs of its market. The main objective of this research was to identify possible approaches that Johnson Controls South Africa (JCI SA) could pursue when implementing a Lean Manufacturing model. In doing this it will improve JCI SA’s manufacturing efficiency and quality, thus giving the organisation a competitive edge over its opposition. The research presented an empirical study of how a Lean Manufacturing model should be implemented in JCI SA. A theoretical and empirical study was conducted on how to successfully implement Lean Manufacturing within an organisation. The main purpose was to establish a theoretical Lean Manufacturing model that the organisation can utilise as a strategic plan to become the global leader in its market place.

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.

Acceptable product quality is one of the central pillars of customer satisfaction, which is key to customer retention and business success. The quest to improve and maintain good product quality is as old as mankind himself. In the beginning of time, quality involved selecting edible plants, to craftsmanship then later to mass production. As time went on, various individuals and institutions made valuable contributions to quality control methods, tools and techniques as we know them today. The International Organisation for Standardisation initiated quality management standards, provide requirements, specifications and guidelines that can be used to ensure materials and products meet a certain quality level. These quality management systems were adopted by the global automotive organisations, adapted and tailored to suit their requirements. The result was the development of ISO/TS 16949, which is a requirement for all direct manufacturing suppliers to the automotive original equipment manufacturers (OEMs), like BMW, TOYOTA and GM. Some OEMs specify additional requirements their supplier base, in case of General Motors, Quality Systems Basics (QSB) is a mandatory quality management systems requirement. QSB is designed by GM to help suppliers reduce product defects, improve internal efficiencies and improve supply chain processes. A quantitative approach was chosen, which utilised an explorative and descriptive survey questionnaire in order to complete the research study. The study will show that the majority of the respondents believed that the implementation of QSB has resulted in positive implications in their manufacturing process and supply value chain.

The lean manufacturing system that evolved in Japan since World War II has leapt across the globe to North America and Europe. The secret success of Japan’s manufacturing machine has been shared. In Europe and America, lean has been identified as a manufacturing best practice that should be adopted to ensure competitive manufacturing efficiency. Many success stories have been told of American companies adopting the Japanese lean tools and techniques. Now, South African manufacturers are implementing the lean manufacturing philosophy, some with more success than others. This research paper explores lean manufacturing implementations at two South African automotive component manufacturers and identifies the critical success factors that have driven the implementation process forward. Commitment from top company executives, extensive training, worker empowerment and other critical success factors for implementing lean manufacturing into a South African environment are identified as a result of the research conducted.

This thesis examines the evolution of postwar industrial relations in postwar Japan from 1945 to 1973. It analyzes the impact of postwar industrial relations institutions on the origins and development of “lean production” or, as it is otherwise known, the Toyota production system. It uses three case studies, Mitsui Coal’s Miike mine in Kyushu, Suzuki Motors in Hamamatsu, and Moriguchi City Hall as an empirical basis for analysis and constructs a schema of industrial relations institutions that challenges the conventional “three pillars” interpretation (lifetime employment, seniority-based wages, and enterprise unions). From a historical perspective there were three distinct stages in the evolution of industrial relations. The first, from 1945-1947 was a labour-dominated period during which unions began to develop a distinct factory regime in which they were equal partners with management and could veto layoffs. Employers rejected this regime, however, and led an offensive against the independent union movement. This offensive was relatively successful in weakening labour and overturning the new institutions, but it engendered further antagonism. Thus the 1950s were characterized by instability in labour relations and new institutions had to evolve out of the workplace. A stable Fordist regime consolidated in the 1960-1973 period. From a comparative perspective and in the context of the development of lean production, the author stresses four institutions: tacit and limited job tenure; a performance-based wage system controlled by management; unions with an enterprise (i.e. market) orientation; and joint consultation. These institutions gave Japanese industrial relations their distinctiveness and also help to explain why lean production developed in Japan. Under the traditional Fordist model, work was broken down into short, repetitive cycles and organized along an assembly line. Employers exerted control by keeping conceptual activities as their mandate and workers were to simply follow instructions. This study found that work itself did not change substantively under lean production but workers participated more in conceptual activities. One of the key reasons for this was that employers in Japan were able to exercise control not only through the division of labour but through the wage system and enterprise unions as well. These mechanisms put discrete limits on the scope of worker innovations. They also limited the benefits workers could expect from the system. Lean production represented a new stage in production, identified as lean, intensified Fordism. / Arts, Faculty of / History, Department of / Graduate

Amid increased competition associated with globalisation, the South African manufacturing sector has come under increased pressure in recent times, with an associated decline in competitiveness. There has been a strong drive by organisations to invest in innovations in the form of Advanced Manufacturing Technologies (AMTs) in an effort to improve their technological status and performance. While investment in AMTs often has a positive impact on performance, numerous accounts of the AMT not meeting expected benefits have been reported. Inability to effectively extract intended benefits from the AMT is often a result of the complex nature of the process, which requires technological considerations and a strategic approach. The objective of this research was to identify the critical organisational factors that impact AMT implementation and establish the relative importance of the factors to provide a guide to managers implementing AMTs to prepare their organisations for the new technology and extract the intended benefits. The research took the form of a quantitative study guided by a self-developed survey and was carried out on manufacturing organisations operating in South Africa. The survey put forward a set of four critical factors that impact AMT implementation, each defined by a proposed set of sub-factors that were validated as accurate definitions in the research. The research established the importance of the proposed factors in contributing to effective AMT implementation, with top management ability and training and education ranked highest, followed by organisational ability a level below and incentives and rewards occupying the lowest level of importance. The importance of these factors was validated through a correlation established between AMT implementation success and the degree to which the organisational factors are evident within an organisation. Organisational readiness of manufacturing companies in South Africa to effectively implement AMTs was also assessed. AMT Considerations related to the size of the organisation and the type of AMT being implemented are also presented along with a summary of key benefits targeted from AMT implementations. Findings were used to develop a model that presents a guide to highlight areas that need attention within an organisation to assist in the allocation of resources during AMT implementations. / Dissertation (MBA)--University of Pretoria, 2014. / lmgibs2015 / Gordon Institute of Business Science (GIBS) / MBA / Unrestricted

Please read the abstract in the section 00front of this document / Dissertation (MSc (Electrical Engineering))--University of Pretoria, 2003. / Electrical, Electronic and Computer Engineering / unrestricted

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El texto completo de este trabajo no está disponible en el Repositorio Académico UPC por restricciones de la casa editorial donde ha sido publicado. / Micro and small businesses in the metalworking sector present a high percentage of informality, and the majority of their production processes are not documented nor standardized. The production approach of Toyota, the enterprise-resource-planning system, and the lean manufacturing system were created for large organizations with sufficient financial resources to successfully implement these models. However, the human factor is a critical component in implementing these models. Therefore, a production management model has been proposed, which is based on lean manufacturing and focuses on the human factor, to increase productivity in the production area of a metalworking company, a small business. The result was that the company’s mentality changed, reaching a productivity of 70% through the use of lean manufacturing tools in the production area.