In a competitive manufacturing environment a firm must be able to simultaneously produce multiple and diverse products, upgrade and redesign its products in short life cycles, and execute efficient production changeovers. This implies that the firm's manufacturing facilities should be capable of efficiently responding to the changes associated with the above abilities. These capabilities are a key requirement for building an agile manufacturing enterprise. To successfully attain these capabilities a firm must evaluate and build flexibility in its manufacturing operations. Success in manufacturing requires the adoption of methods in customer acquisition and order fulfilment processes that can manage anticipated change with precision while providing a fast and flexible response to unanticipated changes. A review of the related literature reveals that though there has been considerable research on the subject of flexible manufacturing, insufficient attention has been devoted to the development of a comprehensive method for designing and building flexible manufacturing (FM) solutions. A significant portion of the FM research and the ensuing industrial applications have focused on highly automated metal working facilities, commonly referred to as flexible manufacturing system or FMS. The objective of this research was to understand what the general understanding of FMS is in the automotive component supplying industry as well as to develop a strategy based on world class principles on how to implement such a strategy. The established strategy will then be used to implement a FMS at Shatterprufe a division of the PFG group. A comprehensive literature study was conducted on Flexible Manufacturing to get a good idea on what it is all about. A questionnaire was designed based on the guidelines in the literature study in order to establish the understanding of FMS within companies in the automotive component supplying industries. Twenty five companies were selected, based on their employee numbers and potential high complexity in the parts that they manufacture. Participating companies must also be part of National Association of Automotive Component and Allied Manufacturers (NAACAM) and supplying directly to all of the local Original Equipment Manufacturers (OEM’s). Eighteen out of the twenty five companies selected did participate and return the questionnaires. Three companies replied stating that they do not have a FMS in place and thus do not want to participate in the research. The completed questionnaires were processed and analysed using Microsoft Office Excel 2003, running on the Windows XP suite of computer packages. The opinions of the various respondents were compared with the guidelines provided in the literature survey, in order to identify how to answer the main questions the author wanted to use as part of selecting an appropriate implementation approach for FMS at Shatterprufe. The following were the main recommendations and conclusions: • It is essential that the executive team at Shatterprufe realises the need of a FM programme. Based on the analysis from the theoretical research as well as from the questionnaire it should not be difficult for them to realise this; • It is recommended that the knowledge gained from the research theory and that of the research questionnaire be used as a guideline for introduction and implementation; • It is recommended that the employees that will be required to implement the FMS are properly trained in the basics of WCM and FMS and that they receive the necessary tools to perform their tasks; • It is essential that everyone throughout the entire organisation is involved from the start in the development, improvement and maintenance of the system; • It is critical that the barriers to implementation be taken seriously at the start of the whole implementation process and plans be put in place to overcome them. Make sure that there is: • proper understanding of the total effort required; • complete management support; • union buy-in; • enough training carried out; • change of priorities; • full commitment and persistence; • development of a good installation strategy; and • insurance of choosing the right approach.
| Identifer | oai:union.ndltd.org:netd.ac.za/oai:union.ndltd.org:nmmu/vital:8592 |
| Date | January 2011 |
| Creators | Mostert, Clive |
| Publisher | Nelson Mandela Metropolitan University, Faculty of Business and Economic Sciences |
| Source Sets | South African National ETD Portal |
| Language | English |
| Detected Language | English |
| Type | Thesis, Masters, MBA |
| Format | xv, 107 leaves ; 31 cm, pdf |
| Rights | Nelson Mandela Metropolitan University |
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