The business environment is dramatically changing. Companies today face the challenge of increasing competition, expanding markets, and rising customer expectations. This increases the pressure on companies to lower costs in the entire supply chain, shorten throughput times, reduce inventories, expand product choice, provide more reliable delivery dates, better customer service, improve quality, and efficiently coordinate global demand, supply and production. Process improvement and the need for it move fast in today’s competitive markets. Methodologies used in business for advancement and remaining competitive are enterprise resource planning and lean. This study was concerned with the perceived production planning control problems at Cataler South Africa. Cataler South Africa manufactures catalytic converters for the Toyota market. The objectives of the study were to evaluate the inventory system, procurement of raw materials, to determine the impact of the need to place urgent orders of raw material, to establish an effective production planning schedule and to ensure timeous delivery of products to customer. The study employed an exploratory research using qualitative methods to analyse the responses of 15 participants at senior level. Several initiatives were identified which would enable the organisation to pursue an effective production planning system. Strategic recommendations were made for the production control department. In terms of implementation, it was recommended that Cataler South Africa commence with inventory policy objectives, supplier and customer delivery monitoring and visualisation, training and communication at all levels to redesign the production control processes and to change the way the department conducts its daily duties. / Thesis (MBA)-Unversity of KwaZulu-Natal, Durban, 2012.

Thesis (MBA)--Stellenbosch University, 2007. / ENGLISH ABSTRACT: Diamond mining started in Kimberley in the early 1870s following the discovery of the various diamond bearing kimberlite pipes. Initial open pit mining was replaced by underground mining as the pits went deeper and the last underground mining eventually ceased in 2005 as a result of economic reasons. The mining of these primary resources created a number of tailing resources (previously called dumps) that are scattered all over Kimberley. These resources still contain diamonds as a result of historical inefficient processing technologies. However, each of these resources have unique geological and metallurgical properties because of the differences in the original kimberlites and the different treatment technologies that were used when the tailing resources were deposited. The tailing resources are mined by a fleet of earthmoving equipment and delivered to one of Kimberley Mines‟ five treatment plants for diamond recovery. Each plant is different in terms of treatment capacity, technologies utilised and overall efficiencies. These differences, combined with the geo-metallurgical properties of each individual resource and the hauling distance from the resource to the plant, determine if the specific resource can be treated profitably through that plant. With this array of resources available, Kimberley Mines is in the fortunate position of having flexibility to maximise the Net Present Value (NPV) of the operation. Unfortunately this flexibility also increases the complexity of finding the optimal solution. Mine Planning is currently conducted with a spreadsheet based input – output model but this model is not able to match the resource properties with the plant parameters and this method results in a plan that may be neither practical nor optimal. The model is also very time-consuming and scenario analyses are therefore very limited. This report presents the development of a mixed integer linear programming model to assist with the development of a practical, optimal mine plan. The model is roughly based on a generic model that addresses facility location and processing plant problems as developed by Barbaro & Ramani (1986); however, the model presented in this report includes a more detailed mass balance within the plant and models how the metallurgical properties of the resources affect the mass balances and overall throughputs. The results of the project indicate that the current spreadsheet based Mine Plan is not practical since it violates two mass balance constraints within the Combined Treatment Plant. The newly developed system is used to generate a mining schedule that does not violate any constraints while still delivering the same net present value and overall throughput. The system also illustrates that the plant can improve the annual throughput by 18.2% by changing one screen size. The system also illustrates that only two of the five plants add value and supports management‟s recent decision that the production through the other plants should cease. In summary: The newly developed system generates an optimal, practical mine plan in less than a tenth of the time required for the old spreadsheet based model. The new system can also do various what-if scenarios which the previous model could not answer. / AFRIKAANSE OPSOMMING: Die ontginning van diamante in Kimberley het in die vroeë 1870s begin na die ontdekking van verskeie diamanthoudende kimberlietpype. Aanvanklike oopgroefmynbou is later vervang deur ondergrondse metodes soos die myne dieper geword het. Die laaste ondergrondse myne het in 2005 produksie gestaak as gevolg van ekonomiese redes. Die ontginning van hierdie primêre reserwes het gelei tot die ontstaan van verskeie uitskotreserwes (voorheen genoem afvalhope) verspreid oor Kimberley. Hierdie reserwes bevat steeds diamante as gevolg van die historiese oneffektiewe aanlegte. Die reserwes het elkeen egter verskillende geologiese en metallurgiese eienskappe as gevolg van die verskille in die oorspronklike kimberliete en die verskillende herwinningstegnologieë wat in gebruik was toe die uitskotreserwes gegenereer is. Die uitskotreserwes word gemyn deur ‟n vloot grondverskuiwingstoerusting en word afgelewer by een van Kimberley Myne se vyf aanlegte vir diamantherwinning. Elke aanleg is uniek in terme van kapasiteit, tegnologieë in gebruik en algehele effektiwiteit. Hierdie verskille, tesame met die geo-metallurgiese eienskappe van elke reserwe en die vervoerafstand van die reserwe na die aanleg bepaal of die spesifieke reserwe winsgewend deur daardie aanleg geprosesseer kan word. Bogenoemde verskeidenheid van hulpbronne gee aan Kimberley Myne die voordeel van buigsaamheid om die Netto Huidige Waarde (NHW) van die myn te maksimeer. Hierdie buigsaamheid vergroot egter die kompleksiteit om die optimale antwoord te vind. Beplanning word tans met ‟n sigblad gebasseerde invoer – uitvoer model gedoen, maar hierdie model is nie in staat om die reserwes se eienskappe by die aanlegte se parameters aan te pas nie. Hierdie metode genereer dus ‟n plan wat moontlik nie prakties of optimaal is nie. Die model is ook tydrowend en scenario analises is dus baie beperk. Hierdie verslag beskryf die ontwikkeling van ‟n gemengde heeltallige lineêre programmeringsmodel vir die ontwikkeling van ‟n praktiese, optimale produksieplan. Die model is losweg gegrond op ‟n generiese model van Barbaro & Ramani (1986) wat fasiliteit posisionering en aanlegprobleme aanspreek. Die model in hierdie verslag bevat egter ‟n meer gedetailleerde massabalans binne die aanleg en modelleer hoe die metallurgiese eienskappe van die reserwes die massabalanse en die algehele kapasiteite beïnvloed. Die resultate van die projek dui daarop dat die huidige sigblad produksieplan nie prakties is nie aangesien dit twee massabalansbeperkings in die Combined Treatment Plant oorskry. Die nuwe stelsel is gebruik om ‟n produksieskedule te genereer wat nie enige beperkings verbreek nie en wat terselfdertyd die aanvanklike netto huidige waarde en totale produksie ewenaar. Die stelsel wys ook dat die jaarlikse kapasiteit met 18.2% verhoog kan word deur een van die sif-groottes te verander. Die stelsel demonstreer ook dat slegs twee van die vyf aanlegte waarde toevoeg en ondersteun bestuur se onlangse besluit dat die produksie deur die ander aanlegte gestaak behoort te word. Ter samevatting: Die nuwe stelsel genereer ‟n optimale, praktiese produksieplan in minder as ‟n tiende van die tyd benodig vir die ou sigblad model. Die nuwe stelsel kan ook verskeie “Wat sal gebeur indien…” scenario‟s hanteer wat die vorige model nie kon beantwoord nie.

Thesis (MBA (Business Management))--Stellenbosch University, 2008. / ENGLISH ABSTRACT: The aim of this paper was to prove the contribution of the Works Order Close-Out Meeting process at Nampak Flexible Ndabeni, through the development of a Close-Out Meeting contribution evaluation model. Although the value of the Close-Out Meeting process is intuitively understood, a formal measurement would underscore the importance of the process. Using a funnel-based analysis, a total of 63 Close-Out Meeting findings was identified for formal benefit review and were categorised into five finding groups. For each of these five groups a contribution measurement methodology was developed. The methodology was rooted in sound management and ERP theory and then applied to the findings in each group. The following key groups were identified and discussed: Incorrect standards. The importance of correct standards was shown, and the potential misstatement due to incorrect standards was quantified. The analysis showed that effective, ongoing variance review can identify errors in standards and that changes can be initiated and authorised in a short timeframe. ERP process review. Findings that specifically addressed lack of proper process were reviewed and real benefit was calculated for three categories, namely information misstatement, risk mitigation and productivity gains. Formulas were developed and applied for the benefit calculation. The analysis showed it is dangerous to assume that processes are cast in stone or fundamentally sound, and that the Close-Out review process not only identifies deficiency of these processes, but initiates corrective action. Shop floor process review. The investigation into findings that addressed process conformance showed that in most cases the process breakdowns related to the accuracy of information captured into the ERP. The impact of poor information, process non-conformance and corrective action was clearly shown. Actions to improve performance. Targeted actions to improve production performance were subdivided into actions that improved productivity and actions that reduced the risk of recurrence of a negative event. Benefits were calculated using established methods, and in both cases the benefit was substantial. Business decision confirmation. The Close-Out Meeting sometimes forced analysis that did not lead to action but to a better understanding of the business reality. What was shown is that the ability to identify, list and analyse findings of this nature added value. By expanding the benefit analysis beyond a simplistic implementation of corrective action, the scope of benefits was increased. The study achieved several objectives. The analysis showed that corrective actions taken by management have a scientific base and that the implementation of corrective actions delivered real business value. This allowed the business to place the Close-Out Meetings in the correct context, as the business could conclude that Close-Out Meetings were fundamental to its continued success. From a theoretical point of view the body of knowledge around Close-Out Meetings was expanded, while the results also supported the Nampak ERP value case. Close-Out Meetings at Nampak Flexible delivered clear, measurable benefits when discussion points were converted to actions that were acted upon by the business. The value was of such a nature to confirm the importance of Close-Out Meetings as a component of good ERP-manufacturing practice. / AFRIKAANSE OPSOMMING: Die doel van hierdie werkstuk was om die bydrae van die "Works Order Close-Out Meeting" proses by Nampak Flexible Ndabeni te bewys met behulp van 'n "Close-Out Meeting" evaluasiemodel. Alhoewel die waarde van die "Close-Out Meeting"-proses intuitief aanvaar word, aksentueer die ontwikkeling van 'n formele maatstaf die belangrikheid van die proses. 'n Evaluasieproses het 'n totaa1 van 63 bevindinge opgelewer vir analise. Die bevindinge is ingedeel in vyf groeperings en vir elke groepering is 'n ste1 maatstawwe ontwikkel ten einde die bydrae van die bevindinge te meet. Hierdie maatstawwe was gebaseer op bestaande, aanvaarde ERP- en bestuursteorie. Die volgende vyf groepe was geidentifiseer en bespreek. Foutiewe standaarde. Die belangrikheid van akkurate standaarde in die stelsel is bewys, en die skaal van informasiefoute as gevolg van verkeerde standaarde is gekwantifiseer. Daar is bewys dat effektiewe, voortdurende variasie-analise foute kan identifiseer en dat die nodige korrektiewe aksie vinnig implementeerbaar is. ERP-proses. Bevindinge wat voortspruit uit swak prosesse is geidentifiseer en die waarde van die korrektiewe aksie is op drie vlakke geanaliseer, naamlik informasiefoute, risikobeheer en produktiwiteitsverbetering. Formules is ontwikkel en toegepas om die waarde van die korrektiewe aksie te bepaal. Daar is bewys dat dit gevaarlik is om aan te neem dat besigheidsprosesse fundamenteel korrek is, en dat die "Close-Out Review"-proses nie net foutiewe prosesse uitgewys het nie, maar ook die nodige korrektiewe aksie gedryf het. Fabrieksvloerproses. Die ondersoek na bevindinge wat prosesafwykings uitgewys het, het aangedui dat afwykings meestal voorgekom het as gevolg van foutiewe informasie in die ERP-stelsel. Die impak van foutiewe informasie, prosesafwykings en inisiatiewe om die akkuraatheid van informasie te verbeter is duidelik gewys. Produksieverbetering. Bevindinge wat gelei het tot inisiatiewe om produksie te verbeter is verdeel tussen produktiwiteitsverbetering en risikobeheer. Die waarde van die inisiatiewe is bereken met die gebruik van ontwikkelde metodes en in beide gevalle was die resultate baie positief. Ondersteuning by besluitneming. Die "Close-Out Meeting"-proses het somtyds gely tot analise wat nie aanieiding gegee het tot korrektiewe aksie nie, maar wel daartoe gelei het dat bestuur se begrip van besigheidsrealiteit verbeter het. Daar is bewys dat 'n proses wat besigheidsinformasie aan bestuur kan weergee ter ondersteuning van bestuursbesluite, waardevol is. Die mate van voordeel wat uit die proses stem is vergroot deur die waarde-analise uit te brei sodat dit meer is as die blote analise van korrektiewe aksie. Die berekende voordeel uit die "Close-Out Meeting"-proses is groter wanneer die hestek van die voordeel vergroot word om meer as net die direkte waarde van korrektiewe aksie in te sluit. Die studie het voldoen aan verskeie doelwitte. Daar is bewys dat bestuursaksie 'n wetenskaplike basis het en die uitvoer van hierdie aksies besigheidswaarde toevoeg. As gevolg hiervan kon die besigheid "Close-Out Meetings" in die regte konteks plaas en tot die slotsom kom dat hierdie proses 'n fundamentele drywer van besigheidsukses is. Ten slotte is die teorie oor "Close-Out Meetings" uitgebrei en die resultate het ook die waarde onderskryf wat Nampak uit sy ERP-implementasie gekry het. "Close-Out Meetings" by Nampak Flexible het duidelike meetbare voordele opgelewer wanneer die probleme wat geidentifiseer is gelei het tot korrektiewe aksie. Die waarde was van so 'n aard dat die belangrikheid van "Close-Out Meetings" as 'n komponent van goeie vervaardigingsbestuur in 'n ERP-konteks duidelik bewys is.

Submitted in fulfilment of the requirements of the degree of Masters of Technology in Cost and Management Accounting, Durban University of Technology, Durban, 2015. / The Stores Division reportedly found it very difficult to control inventories as well as executing roles and responsibilities allocated in the section. The aims of this study were to identify factors affecting the success of inventory control and to assess strategies used by the Stores Division of the eThekwini Municipality in Durban to control inventory stocks. In order to arrive at the deep structure underpinning inventory control, three theoretical frameworks were used, i.e., stock diffusion theory, application control theory and inventory control in theory and practice. This case study was census, descriptive, cross-sectional and predominantly quantitative in nature with only two open-ended questions. The 57 questionnaires were administered by members of staff at the Stores and Procurement Divisions of the eThekwini Municipality in Durban. Data were analysed using descriptive and inferential statistics and categorised according to themes. The IBM Statistical Package for Social Sciences (SPSS) version 21.0 was used to determine statistical results. The findings of the study revealed that employees lack proper training and education and that there is poor inventory control planning, lack of staff communication and lack of procurement time management when processing inventory orders. Respondents also indicated that there are no common strategies in place to control inventories. The study recommends that the Stores Division should consider the levels of staff qualifications, provide more staff training, and improve inventory control planning; communication; time management, and instigate innovative strategies in order to eradicate growing costs of inventory stocks. Moreover, the internal control processes need to be mapped according to the various roles identified.