The integration of automated ore pre-concentration and waste disposal functions into the hard rock metal mining system, prior to treatment by conventional grinding and flotation, is proposed as a novel interpretation of Mine-Mill Integration for improving the economics and environmental impact of exploiting deep, low-grade or otherwise marginal mineral deposits. The proposed approach seeks to reject coarse, barren waste from the ore stream as early as possible in the mining cycle, and safely dispose of it as backfill underground. The concept is proposed as a Lean Manufacturing approach to hard rock mining, as an alternative to improving the economics of mining simply by increasing the mining rate. Lean Manufacturing philosophy seeks to design out overburden, smooth production, and eliminate waste from the system. It is suggested that the introduction of these systems into the hard rock mining process addresses all three of these areas of Lean thinking, and is thus an important approach to be considered for surface or underground mines wishing to simultaneously improve efficiency, economics and environmental performance, thus increasing the life, and the sustainability of the operation. The application of integrated mining, processing and waste disposal systems, where appropriate, is proposed as a strategy for the development of efficient new mining operations, or alternately the expansion of production at existing mines. Technologies specific to the success of the approach such as automated ore pre-concentration systems, composite fill preparation and delivery systems, as well as continuous mechanized mining methods are explored. The impacts and benefits of applying these integrated technologies to the mining system are defined and quantified through research, testwork, engineering design and systems analysis. Custom geo-metallurgical evaluation tools incorporating mineralogical, metallurgical, geophysical and geotechnical methods have been developed to allow the assessment of ores in terms of their potential for the adoption of the proposed approach. A computerized parametric evaluation model has also been developed to quantify the potential impacts and benefits using data from this testwork. A wide range of case studies have been investigated with positive results, and important conclusions are drawn towards the potential for application of the concept as a generalized case. / Applied Science, Faculty of / Mining Engineering, Keevil Institute of / Graduate

The Republic of South Africa’s energy economy is under immense pressure and the main energy utility, Eskom, cannot reliably generate sufficient electrical energy to meet its customer demand. Water security in South Africa is also under threat as the country is currently amidst a water crisis. The South African manufacturing industry is the sector consuming the largest portion of the total energy consumption and second largest portion of the total water consumption (excluding urban use) nationally. Water and energy efficiency improvement is becoming imperative for organisational success as well as national economic sustainability. This is due to the significant increase in the cost of both electrical energy and water in recent years, and the drop in the reserve energy margin below the minimum level required for sustainable operation of energy utilities. The research objective therefore was to develop a Lean-based water and energy efficiency improvement framework for the manufacturing industry to encourage and realise a reduced demand for energy and water in it. A literature review was conducted on the water and energy landscape in South Africa, Lean manufacturing principles and their positive natural influence on water and energy efficiency, and the Value Stream Mapping tool. The survey of water and energy wastes in the manufacturing industry yielded the creation of standardised water and energy waste categories for use in conjunction with the conventional Lean wastes, tools and techniques. The literature survey indicated that the implementation of Lean manufacturing techniques naturally leads to the improvement of energy and water intensity. The researcher hypothesised that there is even greater potential for water and energy savings if a Lean-based tool is developed to specifically focus on the improvement of energy and water efficiency. A framework for this tool was developed through the literature survey. The tool is based on the Value Stream Mapping tool. A practical experiment was then conducted to establish the effectiveness of the tool in the South African manufacturing industry. The experiment design included an outline of the forecasting and statistical validation techniques to ensure the integrity of data utilised for approving or disproving the set hypotheses. The results of the practical experiment yielded positive results, confirming the hypothesis that the implementation of the developed framework will lead to improved energy and water efficiency in the manufacturing industry. After an explanation of the experimental results, the study concluded with recommendations and conclusions based on the findings.

When the current South African government came into power two decades ago they inherited a fragmented health care system whose main focus was on the tertiary care level. The strategy of the current government was to re-focus the whole health care system and prioritize primary health care system. That included setting up district health care systems and building primary health care centres in the areas within the communities in order to make health care accessible to everybody. Due to financial difficulties the majority of the people staying in these communities solely depend on these clinics as they cannot afford to buy health care services in the private sector. The study seeks to assess the current medication supply chain to these clinics with a view of coming up with recommendations that, when implemented, will ensure that the supply of medication by the clinics is able to meet the demands of their patients. Lean management is a system that was started in the manufacturing sector and because of its success there it was later adopted by the service industry. Lean is a system that seeks to eliminate all forms of waste and improve the quality of the service rendered to the satisfaction of the customer/patient. Literature review and discussion of lean implementation is discussed extensively. The findings of the study are presented, analyzed and discussed. In these findings it is noted that the system is functioning very well but there are challenges in these clinics that need to be addressed. Recommendations of how lean management can be implemented successfully to optimize the functioning of the current system are discusse The permission received from the Department of Health to conduct this study came with contractual obligations that the researcher promised to honour. One of those requirement stated clearly that the findings of the study should not be published anywhere without the permission of the Department (see addendums A & C). It is under that premise that the researcher wants to bring this to the attention of the relevant university departments, with the hope of ensuring that this contractual obligation is honoured.

Globalization in the automotive industry exerts enormous pressure on automotive manufacturers and forces many global companies to expand into emerging markets, which results in adopting new ways to manage product design and development. Excellence in product design and development offers an opportunity to gain competitive advantage and can be achieved by implementing Toyota´s Lean Product Development System (LPDS). Although in the last three years Toyota has been severely challenged by the global economic crisis, by a series of recalls resulting in reputation damage and also by natural disasters such as the recent tsunamis - the world can still learn from Toyota´s successes embodied in the lean concept and practices, which are integral to Toyota´s ‘way of life’. The LPDS model (Morgan & Liker 2006) has captured the attention of academics worldwide (including this researcher) thanks to the following key characteristics: shorter development times, less engineering hours involved in development, lower manufacturing costs, higher customer satisfaction and fewer defects reported. In the academic world, lean product development (LPD) is a new field of exploration and thus relevant literature and numbers of studies available are limited. However, scientists are asking questions about successful adaptation and adoption of this model to other environments beyond Toyota. Similarly, the researcher aimed in this thesis to find answers to its main research question, namely: ‘What would be a suitable LPD model for the South African automotive industry?’ South Africa (SA) is a country with a strong manufacturing tradition and although the automotive sector is the third-largest segment in the South African economy and its vehicle market is the largest on the African continent in a global perspective SA´s contribution is relatively small as it produces only 0.61percent of the global motor vehicle volume (OICA 2011). While the country strives to secure sustainable development for the automotive industry and seeks to improve its global competitiveness, companies operating in SA are currently faced with several unique challenges and problems. Lean has been expanding slowly in SA and some companies in the local automotive industry have implemented the lean concept into production areas to improve their operational excellence and performance. However, it is a search for excellence in product development (PD) that could best contribute to improved sustainability for the automotive industry and also provide an important strategic spur towards global competitiveness. The primary intention of this research was to develop an integrated LPD framework tailored for SA´s automotive industry. Considering this, it was necessary to determine current PD capabilities at domestic and international companies operating in SA´s automotive industry so as to examine levels of adaptation of LPD practices. A questionnaire survey and personal interviews involving all seven locally operating Original Equipment Manufacturers (OEMs), including Toyota, as well as 36 local automotive suppliers provided an empirical base for this investigation. This study indicates that SA plays an important supportive role in the global PD context. In spite of a strong manufacturing focus and very limited PD capabilities, SA´s automotive companies have already achieved a high level of ‘leanness’ in product engineering processes. However, on the downside, it appears that industry leaders and senior managers are sceptical about current and future capabilities and opportunities for SA in the designing and developing of global products.

Globalization in the automotive industry exerts enormous pressure on automotive manufacturers and forces many global companies to expand into emerging markets, which results in adopting new ways to manage product design and development. Excellence in product design and development offers an opportunity to gain competitive advantage and can be achieved by implementing Toyota´s Lean Product Development System (LPDS). Although in the last three years Toyota has been severely challenged by the global economic crisis, by a series of recalls resulting in reputation damage and also by natural disasters such as the recent tsunamis - the world can still learn from Toyota´s successes embodied in the lean concept and practices, which are integral to Toyota´s ‘way of life’. The LPDS model (Morgan & Liker 2006) has captured the attention of academics worldwide (including this researcher) thanks to the following key characteristics: shorter development times, less engineering hours involved in development, lower manufacturing costs, higher customer satisfaction and fewer defects reported. In the academic world, lean product development (LPD) is a new field of exploration and thus relevant literature and numbers of studies available are limited. However, scientists are asking questions about successful adaptation and adoption of this model to other environments beyond Toyota. Similarly, the researcher aimed in this thesis to find answers to its main research question, namely: ‘What would be a suitable LPD model for the South African automotive industry?’ South Africa (SA) is a country with a strong manufacturing tradition and although the automotive sector is the third-largest segment in the South African economy and its vehicle market is the largest on the African continent in a global perspective SA´s contribution is relatively small as it produces only 0.61% of the global motor vehicle volume (OICA 2011). While the country strives to secure sustainable development for the automotive industry and seeks to improve its global competitiveness, companies operating in SA are currently faced with several unique challenges and problems. Lean has been expanding slowly in SA and some companies in the local automotive industry have implemented the lean concept into production areas to improve their operational excellence and performance. However, it is a search for excellence in product development (PD) that could best contribute to improved sustainability for the iv automotive industry and also provide an important strategic spur towards global competitiveness. The primary intention of this research was to develop an integrated LPD framework tailored for SA´s automotive industry. Considering this, it was necessary to determine current PD capabilities at domestic and international companies operating in SA´s automotive industry so as to examine levels of adaptation of LPD practices. A questionnaire survey and personal interviews involving all seven locally operating Original Equipment Manufacturers (OEMs), including Toyota, as well as 36 local automotive suppliers provided an empirical base for this investigation. This study indicates that SA plays an important supportive role in the global PD context. In spite of a strong manufacturing focus and very limited PD capabilities, SA´s automotive companies have already achieved a high level of ‘leanness’ in product engineering processes. However, on the downside, it appears that industry leaders and senior managers are sceptical about current and future capabilities and opportunities for SA in the designing and developing of global products.

This treatise investigates the underlying factors influencing productivity at Ford Struandale Engine Plant.

Lean manufacturing provides a fundamental basis for competitiveness in the auto component sector. The implementation and sustainability of the lean philosophy are important aspects when deciding on the adoption of the lean concept within organisations. Various barriers to implementation present themselves during and after lean implementation. These barriers are often related and in some instances they may be converted from an impediment into an enabler of lean within companies. The impact of unions as a negative or positive influence forms a central focus of this research. The influences on the perception of unions and their constituents are studied in relation to other barriers in order to determine their relevance in the Eastern Cape auto sector. A research questionnaire was constructed in line with the selected research design. The application of triangulation in the research design allows for greater depth in the responses from the participants in this research. The quantitative analysis combined with the qualitative thematic analysis provides an excellent means to explore and understand these selected barriers to lean in great detail. It can be concluded that automotive trade unions in the Eastern Cape are a barrier to implementation; however the factor that influences lean the most is the incorrect perception of lean due to ineffective leadership practices among organisational and union leaders, among other barriers. The impact of unions on the acceptance of a lean culture has far-reaching implications for the auto sector that requires a specific implementation approach in order to change perceptions and gain the requisite interest alignment among unions and their constituents.

National Centre for Nano-Structured Materials (NCNSM), one of the National Department of Science and Technology’s nanotech innovation centres houses a characterisation facility which provides a wide array of high-tech materials characterization techniques used in nanotechnology research, to any researchers from any part of South Africa, whether from higher education institutions, government institutions or private firms. In this study the operational review was conducted to identify if the NCNSM Characterisation Facility is delivering on its implementation intent. With operational review organisations are able to explore their internal operations and seek recommendations as to how they can manage and operate more economically, efficiently and effectively. Given that they perform appropriately, allocating their resources properly, and performing within time frame set and using cost-effective measures. BPR was used as a framework to conduct the operational review. BPR is a framework for analysis and design of workflows and process within an organisation. It is an improvement initiative that provides radical change of the business processes in an organizational process. The findings of this study indicated that the NCNSM-CF did not entirely meet its implementation intent but it is striving towards the intention. One of the main reasons for the facility not to meet its intended implementation was the difficulty of the researchers/clients to get access to the facility. The current booking system process contributed significantly to the access problem.

This thesis is focused on the suggestions for the application of maintenance department optimization concept -- Total productive maintenance, in the context of wider concept of lean manufacturing, in the BAEST company. The content of the thesis is to get acquainted with the theoretical background of the lean manufacturing and maintenance, analysis of the current state at the company's maintenance department reflecting the described theoretical background, identification of the potential for improvements by comparing the current state with the theoretically ideal state and coming up with individual recommendations for improvements of the maintenance department in order to make it better and more effective and efficient.

Implementa y aplica Lean Manufacturing en una empresa de confección de ropa industrial para incrementar la productividad. Para esto cartografía la situación actual a través del mapa de la cadena de valor o Value Stream Mapping (VSM) e identifica el ritmo de la demanda del cliente a través de la implementación del Takt Time. / Trabajo de suficiencia profesional