As competition has intensified, many American manufacturers have sought alternatives to rejuvenate their production systems. Cellular manufacturing systems have received considerable interest from both academics and practitioners. This research examines three major issues in cellular manufacturing that have not been adequately addressed: applicability, structural design, and operational design. Applicability, in this study, is concerned with discerning the circumstances in which cellular manufacturing is the system of choice. The methodology employed is simulation and two experimental studies are conducted. The objective of Experiment I, a 2 x 3 x 3 factorial design, is to investigate the role of setup time and move time on system performance and to gain insight into why and how one layout could outperform another. The results of Experiment I suggest that move time is a significant factor for job shops and that workload variation needs to be reduced if the performance of cellular manufacturing is to be improved. Experiment II evaluates the impact of setup time reduction and operational standardization on the performance of cellular manufacturing. The results of Experiment II suggest that cellular manufacturing is preferred if the following conditions exist: (1) well balanced workload, (2) standardized products, (3) standardized operations, and (4) setup times independent from processing times. / Ph. D.

This research examines the relationships between the independent variables; lot size, sequencing rule, and shop type/product mix and the â dependent variables; work-in-process, machine utilization, flowtime, and leadtime. These relationships have seldom been investigated by academicians. There is no satisfactory method available in the literature today that can be used to accurately estimate leadtime. This research developed methods for leadtime estimation. A leadtime estimation method would be invaluable to the production planner, for it would enable the person to decide when the job should be released to the shop. The experimental system considered in this research is an eight machine shop. Three different shop types, a jobshop, modified flowshop, and a flowshop, were modelled. Each shop type had eight different product types being manufactured. Two different sequencing rules, SPT and FIFO, were used. The entire system was analyzed via simulation on an IBM P.C. using SIMAN system simulation concepts. / Master of Science

This thesis presents an approach for solving the problem of determining a near optimal number of machines in order to minimize total cost in a Cellular Manufacturing System. In addition, all aspects and design of a Cellular Manufacturing System are discussed along with other related topics such as Group Technology and Plant Layout as applied to Cellular Manufacturing. / Master of Science

En el marco de un mercado de la electricidad con precios cada vez más altos y donde la participación de fuentes renovables de generación está jugando un papel cada vez más importante, esta tesis supone un enfoque innovador hacia la participación de recursos de demanda en mercados de operación, prestando una atención especial a segmentos industriales como el sector alimentario con un consumo energético intensivo. En primer lugar, esta tesis describe detalladamente la situación actual de los programas de respuesta de la demanda que existen en diferentes partes del mundo. Este estudio permite concluir que los consumidores no han sido tenidos en cuenta suficientemente en la fase de diseño de los programas existentes, lo que ha provocado la infrautilización de recursos de demanda que, actualmente, permanecen sin explorar. Por otro lado, los consumidores no son conscientes del valor que su flexibilidad podría tener para el sistema eléctrico en su conjunto, ignorando que puedan existir otros agentes dispuestos a pagarles a cambio de reducir sus cargas en períodos determinados. Como resultado, esta tesis desarrolla una nueva metodología para explorar y valorar nuevos mecanismos de respuesta de la demanda donde el punto de vista de consumidores, operadores de red y cualquier otro agente interesado pueda ser tenido en cuenta. Esta metodología, basada en la evaluación y análisis detallado de los procesos, proporciona a los consumidores las herramientas adecuadas para evaluar su capacidad para reaccionar al precio de la electricidad, lo que permitiría al regulador poner en valor el beneficio social de dicha flexibilidad si pudiera ser utilizada en mercados de operación, ayudándole a definir los programas necesarios para utilizar de forma adecuada el potencial identificado por los consumidores. La metodología desarrollada en esta tesis ha sido aplicada satisfactoriamente al sub-segmento de la industria cárnica, por lo que varias fábricas pertenecientes a este segmento han sido estudiadas en detalle. En concreto, la factibilidad de las acciones propuestas ha sido probada y validada satisfactoriamente en una fábrica dedicada a la producción de jamón curado en España, en la que se han evaluado diferentes estrategias de flexibilidad. Finalmente, se ha realizado una evaluación económica de la rentabilidad de la aplicación de las acciones de flexibilidad propuestas tanto para el consumidor como para el sistema eléctrico en su conjunto, donde se han considerado los precios reales de los mercados de operación en España, aun cuando los consumidores no puedan participar realmente en dichos mercados en la actualidad. / Alcázar Ortega, M. (2011). Evaluation and Assessment of New Demand Response Products based on the use of Flexibility in Industrial Processes: Application to the Food Industry [Tesis doctoral]. Universitat Politècnica de València. https://doi.org/10.4995/Thesis/10251/10078

This thesis deals with the proposal to support production management information system in the particular company. Based on theoretical knowledge and analysis of the current state of the company and its surroundings, the proposal supports production management information system. The thesis includes the level of strategy, tactics and operations and areas of the planning, organizing, management and control. Proposals should lead to greater effectiveness and efficiency in the processes related to production and thereby to achieve higher profits.

Dissertation submitted in partial fulfilment of the requirements for the degree of Master of Business Administration, Business Studies Unit, Faculty of Commerce, Durban University of Techology, 2007. / Quality improvement is a fundamental and important attribute of a company’s business strategy and competitive positioning. The Durban-based paint factory of Dulux (Pty)Ltd, is the primary manufacturing and distribution site in South Africa. This site has to ensure that the consumers and customers in the target market, are satisfied with the quality of product and service received from the factory. This research focuses on the determination of employee perceptions of quality during 2006 at the paint factory site. In particular, how could these perceptions be effectively used by management as a basis for improving the quality ethic on the site. An improved quality ethic ensures a value- added product and service offer to the target market. The research investigates employee perceptions for various site departments and job grades within the context of several quality themes. Employee perceptions were determined by means of a quantitative survey conducted on the site population using a survey questionnaire. The study shows a primarily positive perception of quality by the employees. The subsequent descriptive and inferential statistical analysis quantifies these perceptions as statistically significant in relation to the research questions that were used in the research. There were some perceptions of quality that highlited potential areas for improvement within the site quality management system and the scope of application. These areas need to be considered by management in order to restore positive perception and support for the quality management system. It is recommended that an annual survey of employee perceptions be conducted by the Quality Assurance department and feedback discussed at the annual quality management review forum. An effective quality improvement and communications strategy can then be determined for implementation. It is also proposed that future research consider conducting a similar study at the service oriented Dulux Alberton site and another survey for the management team at the Durban factory.

Thesis (MIng)--University of Stellenbosch, 2003. / ENGLISH ABSTRACT: TheSouthAfrican economy islargely dependant on small enterprisesas a valuable source of job creation, gross domestic product as well as product development and innovation, However, unfortunately there existsan extremeiy high failure rate among small businesswith 20%of startup businessesfailing within the firstyear of operation, and an almost 60% failure rate within the first6 years of existence, Thesestatisticshave initiated several research studies,and have been the focus of many businessbooks, in itseif, creating a vast industry of small businesssuccesstools and quick fix solutions, When considering the high failure rates of small businesses,the concepts surrounding sustainable development come into question by pure method of association, Sustainable development issueshave become a top priority globally and have moved up the corporate agenda in recent years. When trying to "marry" these two concepts, questions arise regarding the effect of integrating sustainability principles and management systems,with contemporary small businessstrategy. Theaim of thisstudy isto investigate existingcritical successmodels and to integrate some simple initial stages of sustainable development business strategy within these models. Expectantly, some of the principles contained in the formalisation of management systems that address sustainability issues,could be incorporated in traditional management models in an attempt to identify possible interventions and tools that might positivelyimpact on the successrate of small businessenterprises. These concepts would be tested by means of implementing a formal environmental management system (based on the ISO 14001standard) as an initial approach to addressingsustainabilitygoals, as a case study, The successful implementation of an ISO 14001 environmental management system at this small businessenterprise, realised several advantages for the company, and have been used to adapt traditional management models to include for some of the simple concepts of sustainable development. / AFRIKAANSE OPSOMMING: Die Suid Afrikaanse ekonomie is in 'n groot mate afhanklik van klein besighede as 'n waardevolle bron van werkskepping, bruto binnelandse produk, asook van produk ontwikkeling en innovasie, Des nieteenstaande, bestaan daar ongelukkig 'n baie hoe faling syfer onder klein besighede, met 20%van aanvangsbesighede wat mislukbinne die eerste jaar van bedryf en ongeveer 60%van besighede wat mislukbinne die eerste 6jaar van bestaan. Hierdie statistieke het reeds verskeie navorsingstudiesgeinisieer en was reeds die tema van verskeie boeke, wat opsig self 'n reuse industrie genereer van sake sukseshandleidings en kits oplossings vir verskeie probleme, Wanneer hierdie hoe falings statistieke onder klein sake ondernemings oorweeg word, bevraagteken mens die konsepte rakende volhoubare ontwikkeiing, bloot as gevolg van assosiasie,Volhoubare ontwikkeling het in die laaste paar jaar baie aandag geniet op die prioriteitsagendas internationaal, asook van verskeie korporatiewe agendas. As gepoog word om hierdie twee konsepte met mekaar te vereenselwig, ontwikkel daar verskeievrae rakende die effek van die integrering van volhoubare ontwikkelingsbeginselsen verwante bestuurstelsels,met bestaande kiein sake onderneming strategie, Die doel van hierdie studie isom bestaande suksesmodelIe vir klein sake ondernemings te ondersoek, en om sommige van die begin fase beginselsvan volhoubare besigheids strategie, met mekaar te integreer. Daar sou verwag kon word dot sommige van .die konsepte bevat in die formaiisering van bestuurstelselsrakende volhoubare ontwikkeling, ook geinkorporeer kan word binne bestaande traditionele bestuursmodelle, in 'n poging om moontlike ingrypings en gereedskap te identifiseer wat 'n positiewe impak kan he op die suksessyfersvan kleinsake ondernemings. Hierdie konsepte is getoets aan die hand van 'n implimentering van 'n formele omgewingsbestuurstelsel(gebasseer op die ISO14001standaard) as 'ngevalle studie, wat die begin benadering vorm om die doelwitte van volhoubaarheid aan te spreek. Die suksesvolleimplimentering van 'n ISO 14001omgewingsbestuurselsel by 'n klein sake onderneming het verskeie voordele vir hierdie maatskappy tot gevolg gehad. en is gebruik om tradisionele suksesmodelleaan te pas, om voorsiening te maak vir sommige van die konsepte rakende volhoubare ontwikkeling.

Thesis (MBA (Business Management))--Stellenbosch University, 2008. / ENGLISH ABSTRACT: The concept of a business existing to fulfil the wants and needs of the various stakeholders acknowledges that the prime goal of any commercial business is that of profit maximisation and the resultant stock price maximisation (Brigham & Ehrhardt, 2002:10). Any decision by the senior management or the board of an organisation should be primarily in the interest of its shareholders. It follows that any decision that does not add shareholder value subtracts from shareholder value; in other words, decisions must impact the bottom line financially. The manufacturing sector has seen its fair share of methods, interventions and programmes aimed at cost reduction and profit maximisation through a variety of total quality management (TOM), statistical process control (SPC), right/downsizing, efficiency improvements and yield maximisation. One of the most enduring and successful of these has been the advent of the lean manufacturing philosophy, defined as the complete and thorough elimination of waste to reduce the time line from receipt of customer order to delivery. It is a process-focused philosophy and not results focused, the belief being that the elimination of waste from all aspects of the process will ultimately result in financial success. Toyota have developed, and perfected more than most, the concept of lean manufacturing. They have termed their lean initiative the Toyota Production System (TPS). At the core of TPS is the concept of one piece flow controlled by customer pull. Given the success derived from TPS by Toyota it is only natural that other organisations have shown interest and have attempted, in varying degrees of success, to copy the TPS. But the magnitude of attempting to change the philosophy of an organisation in the short term is a daunting task and it is understandable why adopters of a lean way forward have rather turned to the lean tools as drivers of the process and value. The attraction of lean tools is that they can be applied in many areas of an organisation independent of one another. Organisations have a range of needs that need to be satisfied which include growth, increased profits, cash now and talent retention. The need to decide what interventions to apply when and where and what impact to profit and share value is of paramount importance to decision makers of organisations. By analysis of the results of a global industrial packaging company's efforts to implement lean through a tool-based approach, this study attempts to offer guidance to those organisations interested in implementing lean tools. The tools employed comprise four operational and three commercial tools. A financial model examining the impact of the tools on financial metrics is then developed and tested. The results show that the impact of the applied tools impact directly financial metrics used by investors to assess the relative attractiveness of an organisation's shares for the period 2003 to 2007. Further research should be conducted to determine the performance of the organisation for a ten to fifteen-year period to determine future success. / AFRIKAANSE OPSOMMING: Die konsep dat 'n sakeondememing bestaan om die verwagtinge en behoeftes van die onderskeie rolspelers te dien erken dat maksimale wins en die gevolglike optimale aandeleprys die primere doelwitte van enige kommersiele onderneming is (Brigham & Ehrhardt, 2002:10). Enige besluit deur die senior bestuur of the direksie van 'n ondememing behoort dus primer in die belang van sodanige ondememing se aandeelhouers te wees. Gevolglik sal enige besluit wat geen waarde tot die aandeelhouer bied nie, sodanige waarde verminder en moontlik lei tot disinvestering; met ander woorde, besluite moet finansieel 'n invloed op winsgewendheid he. Die vervaardigingsektor het al verskeie metodes, ingrypings en programme beleef wat gemik is op kostevermindering en winsverhoging deur middel van 'n verskeidenheid van algehele kwaliteitsbestuur ("total quality management"), statistiese prosesbeheer ("statistical process control"), herstrukturering deur middel van sogenaamde afskaling ("rightdownsizing"), verbetering van effektiwiteit en opbrengs. Een van die standhoudendste en suksesvolste van hierdie is die skep van die "spilvrye" vervaardigingsfilosofie ("lean manufacturing philosophy") wat gedefinieer word as: die totale en volledige eliminering van verspilling om die tydsverloop tussen die ontvangs van die klient se bestelling tot die aflewering te verminder. Die aanname word gemaak dat die eliminering van verspilling vanuit alle aspekte van die proses uiteindelik finansiele sukses tot gevolg sal he. Die filosofie is dus gefokus op die proses en nie op resultate nie. Toyota het die konsep van "spilvrye"-vervaardiging ontwikkel en, meer as ander, vervolmaak en verwys na hul inisiatief as die "Toyota Production System" of TPS. Sentraal tot die TPS is die konsep van enkel-aaneenlopende produksievloei beheer deur klienteopdrag en -behoefte. As gevolg van Toyota se sukses met die toepassing van die TPS is dit te verwagte dat ander organisasies belangstelling sou toon en met wisselende sukses gepoog het om die TPS na te boots. Om die filosofie van 'n organisasie in die kort termyn te verander is so 'n omvangryke taak dat dit begryplik is waarom nuwe bekeerlinge tot die "spilvrye" -filosofie eerder "spilvrye"-instrumente verkies as die dryfvere van die proses en waarde. Die aantrekkingskrag van "spilvrye"-instrumente is dat dit onafhanklik van mekaar in baie areas van 'n organisasie deur individue, werkspanne of konsultante aangewend kan word. Insluitend groei, die verhoging van wins, kontantvloei en die behoud van talent, het organisasies uiteenlopende behoeftes wat aangespreek moet word. Dit is van die uiterste belang vir besluitnemers van organisasies om te besluit op toepaslike ingryping, wanneer en waar, asook die uitwerking op wins en aandeelwaarde. As 'n poging om belangstellende organisasies te help, bied hierdie studie 'n analise van die resultate voortspruitend uit 'n globale industriele verpakkingsmaatskappy se pogings om die "spilvrye" konsep deur middel van 'n instrument-gebaseerde benadering te implementeer. Die resultate toon dat die impak van die toegepaste instrumente 'n direkte invloed het op die finansiele meetinstrumente, wat deur beleggers aangewend word om die relatiewe aantrekkingskrag van 'n organisasie se aandele vir die tydperk 2003 tot 2007 te bepaal. Om toekomstige sukses te bepaal behoort verdere navorsing egter gedoen te word ten opsigte van die organisasie se prestasie oor 'n tien- tot vyftien-jaar tydperk.

Thesis (MBA)--Stellenbosch University, 2011. / ENGLISH ABSTRACT: Purpose: Literature on World Class Manufacturing is very limited. Some information exists on the concepts behind it, but very little exist on the framework and physical implementation. Also, a lot of information is available on other productivity improvement initiatives but not a lot is mentioned about the implementation thereof and the difficulties experienced during the implementation. This paper aims to provide not only an overview of the framework of World Class Manufacturing as interpreted by ArcelorMittal, but also a case study of such an implementation. Design/Methodology/Approach: The approach taken with this paper is to give an overview of the World Class Manufacturing framework as interpreted by ArcelorMittal and to provide a case study of an actual implementation thereof. Findings: Productivity improvement initiatives have real value for the companies that implement them, but this value can only be sustained if the principles behind them are entrenched in the company’s strategy. Practical Implications: The result of this paper is the design of a Business Management Framework that will support the sustainability of a World Class Manufacturing implementation. Originality/Value: The value of this paper lies not only with the building of the body of knowledge with respect to World Class Manufacturing but also in the design of a new concept for the support of sustained value creation of World Class Manufacturing. / AFRIKAANSE OPSOMMING: Doel: Literatuur oor “World Class Manaufacturing” is baie beperk. Daar is wel literatuur oor die konsepte agter dit, maar daar bestaan baie min literatuur oor die raamwerk asook die fisiese implementering. Daar bestaan ook baie literatuur oor ander produktiwiteits verbetering initiatiewe, maar daarin word daar ook baie min melding gemaak van die implementering asook die probleme wat ondervind word gedurende die tyd. Die verslag se mikpunt is om ’n oorsig te gee van die raamwerk van “World Class Manufacturing” soos wat dit deur ArcelorMittal geinterpreteer word, asook om ’n voorbeeld te gee van so ’n implementering. Ontwerp/Metodologie/Aanslag: Die aanslag wat geneem is met die verslag is om ‘n oorsig te gee van die raamwerk van “World Class Manufacturing” soos wat dit geinterpreteer word deur ArcelorMittal asook om ‘n voorbeeld te gee van die implementering daarvan. Bevindings: Produktiwiteits verbetering initiatiewe lewer regte waarde aan die maatskappye wat dit implementeer, maar die waarde kan net volhou word as die beginsels agter die initiatiewe ingeburger word in die maatskappy se strategie. Praktiese Implikasies: Die resultaat van die verslag is die ontwerp van ‘n Besigheids Bestuur Raamwerk wat die volhoubaarheid van die implementering van “World Class Manufacturing” sal ondersteun. Oorspronklikheid/Waarde: Die waarde van die verslag le nie net in die opbou van die kennis wat beskikbaar is oor “World Class Manufacturing” nie, maar ook in die ontwerp van ’n nuwe konsep for the onderhouding van volhoubare waarde skepping met “World Class Manufacturing”.

Thesis (MBA)--Stellenbosch University, 2007. / ENGLISH ABSTRACT: Product Mix Complexity is a very real issue in modern companies. As globalisation and competition increase, markets mature and the needs of individual consumers get ever more specific, the trend towards more product variety will grow. Product Mix refers to the full range of products that a company offers to its customers. Product Mix Complexity refers to the effect that this product variety has on organizational performance. Understanding and management of this problem is difficult due to the many organizational elements involved, the complicated relationship between these elements and the fact that the problem crosses functional organization boundaries. A company may choose to differentiate itself in the market by offering a broad product mix. To do this effectively the price that can be asked for an item must offset the additional costs brought on by this complexity. This balance between variety that drives sales, and the costs of the added complexity is at the core of the effective management of Product Mix Complexity. The effect of this complexity in manufacturing relates to the loss of scale efficiencies and the need for flexibility in operations. Due to the difficulty in understanding the complex effects of variety, company portfolios tend to proliferate, resulting in a very skewed spread of product contributions where a small % of products contribute a high proportion of company profits. Management processes that continuously evaluate the total profitability of their portfolios from a ‘cost of complexity’ point of view are needed. Cost accounting systems often do not accurately account for this cost of complexity. The effects of Product Mix Complexity are investigated in Cadbury South Africa. The business displays clear signs of having a classical ‘Pareto’ spread of products where a ‘long tail’ of small volume products add very little profit to the business. The Port Elizabeth factory is an above average complex plant within the Cadbury group. It was found that the cost allocation system employed by Cadbury is not accurately allocating costs to products and is thereby aggravating the proliferation of the Cadbury product portfolio. Potential savings by rationalizing the Cadbury product portfolio are identified. A number of recommendations to better manage the presence of Product Mix Complexity are made, both for the business as a whole and for manufacturing specifically. / AFRIKAANSE OPSOMMING: Produkmengselkompleksiteit is alomteenwoordig in moderne besighede. Die neiging tot meer produkverskeidenheid groei namate globalisering, kompetisie en verbruikers se behoeftes na verskeidenheid toeneem. ‘Produkmengsel’ verwys na die volle reeks produkte wat ’n maatskappy aan die mark bied. ‘Produkmengselkompleksiteit’ verwys na die effek wat produkverskeidenheid het op die doeltreffendheid van ’n besigheid. Die probleem is moeilik om te definieer en te verstaan as gevolg van die baie besigheidselemente wat betrokke is, die komplekse verhoudinge tussen hierdie elemente en die multi-funksionele aard van die probleem. Vir strategiese redes wil ’n maatskappy soms ’n groot verskeidenheid produkte aanbied om hom te onderskei in die mark. Om hierdie strategie winsgewend te maak moet die prys wat behaal word opmaak vir die ekstra kostes wat aangegaan word om die breë verskeidenheid te kan aanbied. Die balans tussen die interne koste van verskeidenheid en die voordeel van die verskeidenheid is baie belangrik in die effektiewe bestuur van produkmengselkompleksiteit. Omdat die effek van verskeidenheid moeilik is om te definieer, neig maatskappye daarna om liewer te veel as te min produkte aan te bied. Die gevolg is dikwels ‘n ongebalanseerde distribusie van produkwinsgewendheid waar ’n klein persentasie produkte verantwoordelik is vir die oorgrote meerderheid van die wins. Bestuursprosesse wat produkportefeuljes vanuit ‘n kompleksiteitskoste oogpunt evalueer ontbreek dikwels. Produkkostemodelle neem ook dikwels nie hierdie koste akkuraat in ag nie. Die effek van produkmengselkompleksiteit in Cadbury Suid-Afrika word in hierdie studie ondersoek. Dit is duidelik dat Cadbury Suid-Afrika ’n klassieke ‘Pareto’ effek vertoon waar ’n lang stert van klein produkte baie min tot besigheidswins-gewendheid bydra. Die Port Elizabeth fabriek vertoon ook bogemiddelde kompleksiteit relatief tot ander Cadbury fabrieke. Kompleksiteitskostes word nie akkuraat toegedeel tot produkkostes nie, met die gevolg dat klein produkte aanhoudend tot die produkmengsel gevoeg word. Die potensiële besparings as gevolg van rasionalisasie van die produkportefeulje is bereken. Aanbevelings vir die beter bestuur van produkmengselkompleksiteit word gemaak vir die besigheid as ’n geheel en vir vervaardiging spesifiek.