Thesis (MBA (Business Management))--University of Stellenbosch, 2009.

Thesis (MBA (Business Management))--University of Stellenbosch, 2009. / ENGLISH ABSTRACT: In the face of global competition manufacturers are increasingly finding themselves having to redefine the way they do business. Despite this, and while lean manufacturing has been widely adopted as an inherently superior form of manufacturing when compared to mass production, many companies continue to operate according to a traditional mass production philosophy. This research aims to validate and quantify the existence of a correlation between the presence of lean manufacturing and improved performance in important financial indicators with a view to encouraging the more rapid adoption of lean manufacturing. The intended outcome of this research is therefore firstly an analysis that either confirms or refutes the existence of a correlation between selected lean manufacturing practices and selected financial indicators, and secondly a quantification of the strength of the identified relationship, if any. There are four sub-problems that were identified as being central to the research aims. The first relates to the identification of foundational principles associated with lean manufacturing, while the second relates to the identification of manufacturing practices associated with each principle that can be observed and tested for. The third entailed the evaluation of existing literature on links between lean manufacturing and financial performance. The fourth entailed the development of a set of hypotheses and methodology for the testing of relationships between lean manufacturing practices and financial indicators. The four principles, and their associated practices, were as follows: • Just In Time: kanban; • Total Quality Management: andon and poka-yoke; • Continuous improvement: standardisation of work practices, green areas and suggestion schemes; and • Team-based work organisation: teams, single-piece flow between team members and team leader roles. The review of existing literature provided some guidance in respect of financial performance measures that should be included in the study, but fell short of confirming the type of relationships and correlations sought for the purpose of this research. Data on the financial performance of 22 automotive component manufacturers were obtained from the Benchmarking and Manufacturing Analysts SA (Pty) Ltd’s benchmarking database while data on lean manufacturing practices were obtained through structured observations at the 22 companies between January 2008 and December 2008. Through evaluating Spearman rank correlation coefficients conclusive findings were obtained in respect of the existence of a relationship and a positive correlation between each of the following pairs of variables: • Kanban and average growth in sales; • Kanban and change in Return on Investment; • Andon and operating profit as a percentage of sales; • Poka-yoke and operating profit as a percentage of sales; • Poka-yoke and growth in sales; • Green areas and operating profit as a percentage of sales; and • Standardisation of work practices and operating profit as a percentage of sales. During the analysis and interpretation of the findings value chains dynamics, operational measures, and control variables were cited as key considerations for further research in this field. The paper concludes by suggesting that a study of this nature replicated in the automotive industry in a different economy would likely result in similar outcomes, but that the same outcomes may not necessarily be obtained if the study was replicated in a different industry in the same economy. / AFRIKAANSE OPSOMMING: Met die uitdagings van globale mededinging en vrye toegang tot wêreld markte is vervaardigers blootgestel aan die behoefte om hulle besigheidsprosesse voortdurend te vernuwe en te optimiseer. Ten spyte van die feit dat “Lean Manufacturing” spesifiek in die vervaardigings industrie aanvaar is as die voorkeur model bo die meer tradisionele massa produksie model sukkel maatskapye steeds met die implimentering daarvan. Die doel van hierdie navorsing is om te toon dat daar ‘n verwantskap bestaan tussen die beginsels van “Lean Manufacturing” en die winsgewindheid van maatskappye. Meer spesifiek word daar gesoek na sleutel finansiële aanwysers in die besigheid, en hulle verwantskap met geselekteerde “Lean Manufacturing” beginsels. Daar word gepoog om die verwantskappe te kwantifiseer, en hierdie resultate dan te gebruik as basis vir die motivering om hierdie beginsels verder en vinniger in die vervaardigings industrie te implimenteer. Vier subprobleme is geidentifiseer om die voorgestelde navorsing logies te benader. Die eerste hou verband met die identifisering van die kern beginsels van “Lean Manufacturing”, en die tweede met die identifisering van vervaardigings praktyke wat assosieer kan word met elkeen van die beginsels. Die derde subprobleem is die analise en vewerking van bestaande literatuur met die doel om die verwantskap tussen die identifiseerde kern beginsels van “Lean Manufacturing” en finansiële indikatore te evalueer. Laastens word ‘n hipotese ontwikkel om die identifiseerde verwantskappe te toets en te evalueer. Die vier beginsels en die assosieërde praktyke is: • “Just In Time”: kanban; • Algemene Kwaliteits Bestuur: andon en poka-yoke; • Voortdurende Verbetering: standardisering van werksprosesse; en • Spangebaseerde Organisasies: Spanwerk. Die bestudering van bestaande literatuur het ‘n riglyn geskep vir van die finansiële indikatore wat in ag geneem moet word in die studie. Dit het wel geblyk dat die tipe verwantskap nie duidelik definieer is nie. Die finansiële data van 22 motor komponent vervaardigers is verkry van Benchmarking and Manufacturing Analysts SA (Pty) Ltd’s se databasis. Die data oor “Lean Manufacturing” is verkry deur gestruktureerde waarnemings en onderhoude by dieselfde 22 maatskapye oor die tydperk Januarie 2008 tot Desember 2008. Deur die evaluering van “Spearman rank” korrelasie koëfisiënte kon ‘n korrelasie tussen die volgende veanderlikes verkry word: • Kanban en die gemiddelde groei in verkope; • Kanban en die verandering in die opbrengs op belegging; • Andon en die operasionele wins as ‘n persentasie van verkope; • Poka-yoke en die operasionele wins as ‘n persentasie van verkope; • Poka-yoke en die groei in verkope; • Groen areas en die operasionele wins as ‘n persentasie van verkope; en • Standardisering van werksprosedures en die operasionele wins as ‘n persentasie van verkope. Na aanleiding van die analise en interpretasie van die bevindinge opgelewer deur die studie word die verdere bestudering van die veld sterk aanbeveel. Waardeketting dinamika, operasionele maatstawwe, en beheer veranderlikes is identifiseer as kernaspekte van so ‘n verdere ondersoek. Dit moet egter benadruk word dat die herhaalbaarheid van die studie moontlik sal wees in ander ekonomiese toestande, maar nie noodwendig dieselfde resultate sal lewer vir ander industrieë nie.

This study uses simulation to examine differences between fixed sampling interval (FSI) and variable sampling interval (VSI) Shewhart X-bar control charts for processes that produce positively autocorrelated data. The influence of sample size (1 and 5), autocorrelation parameter, shift in process mean, and length of time between samples is investigated by comparing average time (ATS) and average number of samples (ANSS) to produce an out of control signal for FSI and VSI Shewhart X-bar charts. These comparisons are conducted in two ways: control chart limits pre-set at ±3σ_x / √n and limits computed from the sampling process. Proper interpretation of the Shewhart X-bar chart requires the assumption that observations are statistically independent; however, process data are often autocorrelated over time. Results of this study indicate that increasing the time between samples decreases the effect of positive autocorrelation between samples. Thus, with sufficient time between samples the assumption of independence is essentially not violated. Samples of size 5 produce a faster signal than samples of size 1 with both the FSI and VSI Shewhart X-bar chart when positive autocorrelation is present. However, samples of size 5 require the same time when the data are independent, indicating that this effect is a result of autocorrelation. This research determined that the VSI Shewhart X-bar chart signals increasingly faster than the corresponding FSI chart as the shift in the process mean increases. If the process is likely to exhibit a large shift in the mean, then the VSI technique is recommended. But the faster signaling time of the VSI chart is undesirable when the process is operating on target. However, if the control limits are estimated from process samples, results show that when the process is in control the ARL for the FSI and the ANSS for the VSI are approximately the same, and exceed the expected value when the limits are fixed.

Byggarbetsplatser med flera språk och kulturer representerade innebär utmaningar för kommunikationen kring arbetsmiljö och säkerhet. Under 2015 sände utländska arbetsgivare drygt 18 000 arbetstagare till Sverige för att utföra byggnadsarbeten. Med bakgrund i de närmaste årens mål för bostadsbyggande och den planerade utbyggnaden av infrastrukturen, spås ytterligare 60 000 byggnadsarbetare krävas varje år. För att möta de utmaningar som ökningen kan komma att innebära krävs studier om svenska byggarbetsplatser med utländsk arbetskraft. Denna studie är ur den svenska produktionsledningens perspektiv och syftar till att öka förutsättningarna att skapa en god arbetsmiljö för utstationerade arbetstagare på byggarbetsplatsen. Studien genomfördes i fyra delar med olika angreppssätt för att identifiera vilka utmaningar som uppstår med utländska underentreprenörer, och hur de kan hanteras. En omfattande litteraturstudie genomfördes och samtal med branschmänniskor fördes för att skapa en teoretisk grund. Fallföretagets ledningssystem utforskades som en sorts nulägesanalys för att skapa en utgångspunkt för diskussionen. Slutligen genomfördes intervjuer med åtta produktionsledande tjänstemän från fallföretaget. Förhoppningsvis kan rapporten bidra med mer kunskap kring tvärkulturell kommunikation på byggarbetsplatser och samordning av säkerhetsarbetet med utländska underentreprenörer. Diskussionen kretsar främst kring internationella inköp, språk och kommunikation, arbetsplatsintroduktioner samt daglig styrning. Tydligt avgränsade entreprenader och uppföljning av ställda krav verkar vara förutsättningar för ett fungerande arbete med utländska underentreprenörer. Utstationerade arbetstagare bör genomgå en gedigen arbetsplatsintroduktion och involveras fullt ut i daglig styrning för att skapa delaktighet och ansvarskänsla samt undanröja säkerhetsrisker. På sikt bör engelska nyttjas som arbetsspråk även i normalstora byggprojekt. / Building sites with multiple languages and cultures represented create challenges for the communication about work environment and safety. In 2015 foreign employers sent more than 18 000 workers to Sweden to carry out construction work. According to the next years' objectives for housing construction and the planned expansion of the infrastructure, it is predicted that an additional 60 000 construction workers are needed each year. To meet the challenges that the increase may imply, studies on Swedish building sites with foreign labor are needed. This study is from the Swedish production management’s perspective, and aims to increase the conditions to create a good work environment for posted workers on the building site. The study was carried out in four parts with different approaches to identify the challenges which arise with foreign subcontractors, and how they can be managed. A comprehensive literature study was conducted and discussions with industry people were carried out to create a theoretical basis. The studied company’s management system was explored as a sort of situation analysis to create a basis for discussion. Finally, interviews were conducted with eight production leading officials from the studied company. Hopefully, the report can contribute with more knowledge about cross-cultural communication at building sites and coordination of the safety work with foreign subcontractors. The discussion mainly revolves around the international procurement, language and communication, workplace introduction and daily management. Clearly defined contracts and monitoring requirements seem to be prerequisites for functioning work procedures with foreign subcontractors. Posted workers should pass through a thorough workplace introduction and be fully involved in the daily management to create participation and a sense of responsibility, and eliminating safety risks. Over time, English should be used as a working language even in normal-sized building projects.

L’amélioration de la performance du secteur médico-social nécessite des outils de pilotage aptes à donner rapidement et de façon synthétique une vision claire et quantifiée des activités réalisées en direction des usagers. Or, il n’existe pas aujourd’hui d’outils satisfaisants permettant un pilotage des activités au niveau de chaque structure, mais également au niveau de l'organisme gestionnaire. L’objet du travail de recherche est de concevoir des outils pour l’aide au pilotage et au suivi des activités dans le secteur médico-social permettant d’améliorer la vision actuelle du secteur médico-social trop cloisonné. En relation étroite avec Ressourcial (ancien département du système d’information de la Fondation OVE), ce travail s’inscrit dans le cadre d’une thèse CIFRE et constitue l'une des premières thèses des sciences de l'ingénieur qui s'attaquent aux problèmes d'organisation dans le secteur médico-social. Le premier enjeu scientifique de cette recherche est de proposer une démarche formelle et structurée de suivi des activités réalisées dans ces établissements. L’approche proposée devra être capable de rendre compte d’une typologie d’activités au spectre très large ; activités réalisées par des établissements ayant des modes de fonctionnements, et des cultures métiers, fortement hétérogènes. Sur ce volet, le verrou scientifique de ce travail est celui l’agrégation sur un même modèle, de modes de fonctionnement intrinsèquement hétérogènes. Le second enjeu scientifique de cette thèse est celui du développement d’approches innovantes pour l’analyse de ces données de suivi et pour l’aide au management de ces structures à partir de ces mêmes données. / Improving the performance of medico-social sector requires management tools capable of quickly and synthetically provide a clear and quantified view of activities towards the users. Unfortunally, today does not exist a satisfactory tools to control activities in each structure, as neither at the level of the managing organization. The object of the research work is to develop tools to aid management and monitoring of activities in the medico-social sector in order to improve the current vision of the medico-social sector too compartmentalized. Closely related to Ressourcial (former information system department of OVE Foundation), this work is part of a CIFRE thesis and is one of the first theses of engineering sciences that address to organizational problems in the medical-social sector. The first scientific challenge of this research is to propose a formal and structured approach to monitoring activities in these institutions. The proposed approach should be able to realize a typology of activities in a very broad spectrum; activities performed by institutions with operating modes, and business cultures, highly heterogeneous. On this aspect, the scientist lock of this work is that the aggregation on the same model, intrinsically heterogeneous operating modes. The second scientific challenge of this thesis is the development of innovative approaches for analyzing these monitoring data and to aid management of these structures from the same data.

Submitted by Patrícia Valim Labres de Freitas (patricial) on 2016-04-06T19:43:58Z No. of bitstreams: 1 Guilherme Luiz Cassel_.pdf: 1164228 bytes, checksum: 276ddaee3cb0da38553e1b77fca315d5 (MD5) / Made available in DSpace on 2016-04-06T19:43:58Z (GMT). No. of bitstreams: 1 Guilherme Luiz Cassel_.pdf: 1164228 bytes, checksum: 276ddaee3cb0da38553e1b77fca315d5 (MD5) Previous issue date: 2010-03-24 / UNISINOS - Universidade do Vale do Rio dos Sinos / Esta dissertação apresenta uma proposta de Método para aplicação das leis da filosofia Factory Physics, proposta por Hopp e Spearman (2000), para melhorar Sistemas de Produção. O objetivo deste método é o de resolver problemas dos sistemas de produção a partir da aplicação das leis apresentadas em Factory Physics, de uma maneira sistemática, iniciando com a classificação dos problemas de produção a partir dos objetivos de desempenho propostos por Slack (1993). A metodologia de pesquisa utilizada é baseada em Design Research, que é estruturado a partir de um ciclo de cinco etapas, a saber: (i) consciência do problema; (ii) tentativa de design; (iii) desenvolvimento do artefato; (iv) avaliação do artefato; e (v) conclusão. O método de trabalho foi estruturado em treze etapas, nas quais foram desenvolvidas três versões do método proposto, em função dos sucessivos refinamentos que o método utilizado propõe para o desenvolvimento de (bons) artefatos. Para embasar a pesquisa, o referencial teórico versa sobre temas como sistemas de produção, abordagens técnicas, técnicas para mapeamento e implementação de melhorias, modelagem empresarial, e uma profunda revisão da literatura sobre Factory Physics, e após é realizada uma apresentação dos elementos desenvolvidos para o método, a partir destes conceitos apresentados anteriormente. O trabalho limita-se a apresentar o método (artefato) refinado após as três rodadas de desenvolvimento de acordo com o método de trabalho, sem a pretensão de validá-lo, deixando esta tarefa para trabalhos futuros. Com relação à metodologia Design Research, o presente trabalho visa contribuir apresentando uma análise crítica deste, no que tange ao seu uso, para pesquisas em Engenharia de Produção. Por fim, o resultado da presente pesquisa compreende o método proposto para aplicação das leis de Factory Physics, de modo a promover melhorias em sistemas de produção a partir da abordagem apresentada por Hopp e Spearman (2000), e o aprendizado e artefatos decorrentes do esforço de desenvolvimento neste trabalho. / This dissertation presents a method proposal for Factory Physics laws application, which is a philosophy proposed by Hopp and Spearman (2000), to improve production systems. The method’s objective is solve production systems problems using a application of these laws presented on Factory Physics philosophy, from a systematic viewpoint, starting with the production problems classification by performance objectives perspective, proposed by Slack (1993). The research methodology adopted is based on Design Research, which is structured by five steps: (i) awareness of problem; (ii) suggestion; (iii) artifact’s development; (iv) artifact’s evaluation; and (v) conclusion. The work method was planned with thirteen work stages, where were developed three versions of the method proposed, because of the successive refinements, proposed by Design Research methodology, in order to develop (good) artifacts. To research basement, the theoretical reference present themes like production systems, technical approaches, techniques for mapping and improvement implementation, systems modeling, and a deep bibliography revision about Factory Physics, and after that is made a presentation of the elements developed to the method, using these concepts, presented earlier. This dissertation refrains to make a method’s (artifact’s) presentation, refined after three development cycles according research method, without a validation pretension, leaving this task for future researches. Regarding Design Research methodology, this dissertation seeks for a contribution in this sense, presenting a critical analysis of its use for researches in Production Engineering. After all, the results of this dissertation includes, besides the proposed method for Factory Physics Laws Application, in order to promote improvements on production systems from the philosophy proposed by Hopp and Spearman (2000), the knowledge and artifacts generated in this research effort.

This study attempts to examine and comprehend the connection between human resources management (HMR) practices and effective supply chain management (SCM) implementation by means of a conceptual framework and construct developed through a literature study and previous studies conducted in this area. The focus of this study was to determine whether a South African automotive manufacturer, implements identified human resources practices and to establish to what extent these practices enhance effective supply chain management implementation. A quantitative research approach was used to conduct this study. A census survey was used to collect data. Electronic data was collected using a monkey survey, and paperbased questionnaires were collected by the researcher at the participating organisation. Seven hypotheses were formulated to guide this study. The data analysis of this research was done for the purpose of testing these hypotheses and achieving the empirical research objectives. The findings from descriptive statistical analysis summarised the strong HR practices which facilitate the implementation of effective supply chain management in the participating automotive manufacturing organisation, and also focused on weak HR practices which might hinder the implementation of effective supply chain management. Some areas in which improvement is possible were identified. By taking into account that this study focused on one leading South African automotive manufacturer, further research is recommended with an expansive scope of South African automotive manufacturing organisations. The study aimed to provide recommendations on the adoption of human resource management practices for the purpose of facilitating the implementation of an effective supply chain management. It is of crucial value for the participating South African automotive manufacturing organisation to apply the study’s findings (The South African manufacturer should revise its compensation practices by ensuring that compensation is comparable to what other employees in similar jobs elsewhere are being paid, and it should also provide a sociable and transparent working environment to its workers). / Business Management / M. Com. (Business Management)

Das zu entwickelnde Konzept zielt darauf ab, ausgehend von definierten Produktionsverfahren, -prozessen und den dafür qualitativ bestimmten Maschinen und Anlagen Erkenntnisse zur notwendigen Anzahl und den resultierenden Kosten zu ermitteln. Mit der Entwicklung des Konzepts soll ein Beitrag zur Schaffung eines unternehmensziel- und strategiekonformen Wertschöpfungsprozesses über alle Bereiche des Produktionsmanagements produzierender Unternehmen geleistet werden. Den Kern des Konzepts bildet die dynamische Dimensionierung, die Belastungsänderungen des Produktionssystems über die Zeit berücksichtigt. Der Schwerpunkt liegt dabei auf der Gestaltung eines wirtschaftlich sinnvollen Maßes an Flexibilität und Wandlungsfähigkeit. Weiterhin wird eine Automatisierung des Planungsprozesses in Verbindung mit dem Einsatz von Optimierungstechniken und Kostensimulation angestrebt. Anhand unterschiedlicher Szenarien erfolgt eine Gegenüberstellung des neu entwickelten Konzepts mit bestehenden Verfahren. / The concept which has been developed is based on defined production methods and production processes which are necessary for quality machinery and equipment in order to identify specifically, the number of machines required and the resulting costs. The developed concept contributes to creating a business goal and strategy-driven value creation process in all areas of production management of the manufacturing company. Since the core concept is dynamic dimensioning, it is imperative to take into account the load of the production system and how it changes over time; and is therefore both flexible and adaptable. Furthermore, automation of the planning process in conjunction with the use of optimization techniques and simulation cost is sought. Different scenarios allow the comparison of newly developed concepts with a variety of procedures which already exist.

This thesis illustrates analysis of the influence of the non-machining processes on product quality by experimental design and statistical analysis. For the analysis objective / dishwasher production in Arcelik Dishwasher plant is examined. Sheet metal forming processes of dishwasher production constitutes the greatest portion of production cost and using the Pareto analysis technique / four pieces among twenty six pieces are determined to be investigated. These four pieces are the U Sheet, L Sheet, Inner Door and Side Panel of the dishwasher. By the help of the flow diagrams production process of the determined pieces are defined. Brainstorming technique and cause&amp / effect diagrams are used to determine which non-machining process parameters can cause pieces to be scrapped. These parameters are used as control factors in experimental design. Taguchi&amp / #8217 / s L16(215) orthogonal array, Taguchi&amp / #8217 / s L16(215) orthogonal array using S/N transformation and 28-4 fractional factorial design are used on purpose. With repetitions and confirmation experiments the effective parameters are determined and optimum level of these parameters are defined for the improvements on scrap quantity and quality of production.

Organizational communication research indicates group member participation increases as the legitimate power differences among group members decreases. Lean principles and practices indicate Kaizen Event members will contribute regardless of legitimate power levels, due to member training, education, and the Lean team-oriented culture. Further study is needed to determine if Lean culture and training maximize group member contribution, or if legitimate power levels in Lean environments manipulate participation. The focus of this case study is a central Kentucky Lean manufacturing organization that practiced Lean principles for at least three years and completed a Kaizen Event within twelve months previous to the beginning of the study. The participating organization indicated the legitimate power levels of Kaizen Event members. Kaizen Event members received a voluntary survey consisting of Likert scalescored questions regarding his or her perceptions of level of participation, encouragement and opportunity to participate, comfort in participating, and the degree the group listened to the member. The results of the survey indicated participation in the Kaizen Event groups did not significantly differ among different legitimate power levels.