A causal analysis to investigate low production efficiency in the tyre manufacturing industry in South Africa
- Authors: Bruinders, Bramwill Bertram
- Date: 2021-04
- Subjects: Industrial efficiency , Production management , Lean manufacturing -- South Africa
- Language: English
- Type: Master's theses , text
- Identifier: http://hdl.handle.net/10948/50977 , vital:43177
- Description: The evolution of tyre manufacturing in South Africa went back to the early 1930s and matured technologically, becoming automated in the 1960s. The tyre industry in South Africa is worth approximately R30bn per annum and is one of the major supporting industries for domestic vehicle manufacturers. The local industry manufactures only 11 million tyres but can manufacture 18 million tyres per annum. The tyre industry thus plays a crucial role in South Africa’s economic development. Consumers are opting to buy cheaper imported tyres even though tyres are essential purchases. Therefore, the major tyre manufacturers must compete against an estimated 200 importers of various brands, most from China and Japan. The excess local capacity and increasing volume of imports put the local tyre manufacturers under severe pressure to grow their market share, reduce operational cost and achieve economies of scale. The study’s general objective was to conduct a root cause analysis of South African tyre manufacturers’ underlying issues resulting in low production efficiencies. This study used critical manufacturing principles such as traceability, knowledge of lean principles, lean implementation challenges, Total Quality Management, organisational buy-in, waste and rework and maintenance planning that constitute tools of lean practices. These principles provided an opportunity to adopt efficient manufacturing practices in tyre manufacturing companies and help organisations identify improvement areas. A questionnaire was developed and distributed electronically to 93 respondents employed in the tyre manufacturing industry in South Africa. The study addressed product traceability, investigated the quality measures in place, and examined the influence of the workforce’s attitude and morale on productivity, and determined management’s influence on decision-making. The key findings indicated that traceability, lean implementation challenges and organisational buy-in played a significant role in improving production efficiency. Recommendations were made to management to ensure that they lead by example and enhance these key constructs to foster their growth. , Thesis (MBA) -- Faculty of Business and Economic Sciences, Business Administration , 2021
- Full Text:
- Date Issued: 2021-04
- Authors: Bruinders, Bramwill Bertram
- Date: 2021-04
- Subjects: Industrial efficiency , Production management , Lean manufacturing -- South Africa
- Language: English
- Type: Master's theses , text
- Identifier: http://hdl.handle.net/10948/50977 , vital:43177
- Description: The evolution of tyre manufacturing in South Africa went back to the early 1930s and matured technologically, becoming automated in the 1960s. The tyre industry in South Africa is worth approximately R30bn per annum and is one of the major supporting industries for domestic vehicle manufacturers. The local industry manufactures only 11 million tyres but can manufacture 18 million tyres per annum. The tyre industry thus plays a crucial role in South Africa’s economic development. Consumers are opting to buy cheaper imported tyres even though tyres are essential purchases. Therefore, the major tyre manufacturers must compete against an estimated 200 importers of various brands, most from China and Japan. The excess local capacity and increasing volume of imports put the local tyre manufacturers under severe pressure to grow their market share, reduce operational cost and achieve economies of scale. The study’s general objective was to conduct a root cause analysis of South African tyre manufacturers’ underlying issues resulting in low production efficiencies. This study used critical manufacturing principles such as traceability, knowledge of lean principles, lean implementation challenges, Total Quality Management, organisational buy-in, waste and rework and maintenance planning that constitute tools of lean practices. These principles provided an opportunity to adopt efficient manufacturing practices in tyre manufacturing companies and help organisations identify improvement areas. A questionnaire was developed and distributed electronically to 93 respondents employed in the tyre manufacturing industry in South Africa. The study addressed product traceability, investigated the quality measures in place, and examined the influence of the workforce’s attitude and morale on productivity, and determined management’s influence on decision-making. The key findings indicated that traceability, lean implementation challenges and organisational buy-in played a significant role in improving production efficiency. Recommendations were made to management to ensure that they lead by example and enhance these key constructs to foster their growth. , Thesis (MBA) -- Faculty of Business and Economic Sciences, Business Administration , 2021
- Full Text:
- Date Issued: 2021-04
A model for assessing the anticipated relative financial impact of implementing the tools of lean manufacturing on a manufacturing concern
- Authors: Francis, Merwin
- Date: 2011
- Subjects: Production management , Manufacturing processes , Production planning , Industrial efficiency , Total productive maintenance
- Language: English
- Type: Thesis , Masters , MTech
- Identifier: vital:8972 , http://hdl.handle.net/10948/1326 , Production management , Manufacturing processes , Production planning , Industrial efficiency , Total productive maintenance
- Description: Lean manufacturing has seen its creators, Toyota, rise from insignificance in the middle of the previous century, to the biggest selling car manufacturer in the world today. Another Japanese car manufacturer, Honda, which has also been practising the principles of lean avidly during the last few decades, has also made huge strides towards becoming a dominant force in the car market. These Japanese companies‟ adoption of lean has seen many of their mass producing United States (US) and European counterparts struggle for survival. Maynard (2003:10) predicted that by the end of the decade, at least one of the „Big Three‟ auto makers in the US – Chrysler, Ford, and General Motors (GM) – would be forced to undertake significant restructuring to continue in operation. At the time of this writing all indications are that this prediction will come true. GM is in the process of major shareholding restructuring in an attempt to keep the company afloat, having run up insurmountable debts in the face of the current global economic downturn. Adopting the lean methodology has become a matter of necessity. The continued use of mass production methods alone is no longer viable; companies need to also employ lean methods intelligently in order to remain competitive. This study is regarded as a crucial endeavour to assist operations managers of manufacturing concerns in developing lean implementation strategies which will maximise the benefits to the organization.
- Full Text:
- Date Issued: 2011
- Authors: Francis, Merwin
- Date: 2011
- Subjects: Production management , Manufacturing processes , Production planning , Industrial efficiency , Total productive maintenance
- Language: English
- Type: Thesis , Masters , MTech
- Identifier: vital:8972 , http://hdl.handle.net/10948/1326 , Production management , Manufacturing processes , Production planning , Industrial efficiency , Total productive maintenance
- Description: Lean manufacturing has seen its creators, Toyota, rise from insignificance in the middle of the previous century, to the biggest selling car manufacturer in the world today. Another Japanese car manufacturer, Honda, which has also been practising the principles of lean avidly during the last few decades, has also made huge strides towards becoming a dominant force in the car market. These Japanese companies‟ adoption of lean has seen many of their mass producing United States (US) and European counterparts struggle for survival. Maynard (2003:10) predicted that by the end of the decade, at least one of the „Big Three‟ auto makers in the US – Chrysler, Ford, and General Motors (GM) – would be forced to undertake significant restructuring to continue in operation. At the time of this writing all indications are that this prediction will come true. GM is in the process of major shareholding restructuring in an attempt to keep the company afloat, having run up insurmountable debts in the face of the current global economic downturn. Adopting the lean methodology has become a matter of necessity. The continued use of mass production methods alone is no longer viable; companies need to also employ lean methods intelligently in order to remain competitive. This study is regarded as a crucial endeavour to assist operations managers of manufacturing concerns in developing lean implementation strategies which will maximise the benefits to the organization.
- Full Text:
- Date Issued: 2011
Implementing lean manufacturing to improve production efficiency in the manufacturing operations at the Aspen General facility
- Authors: Jozaffe, Lyndon Brian
- Date: 2006
- Subjects: Production management , Industrial efficiency
- Language: English
- Type: Thesis , Masters , MBA
- Identifier: vital:8557 , http://hdl.handle.net/10948/529 , Production management , Industrial efficiency
- Description: South African producers are constantly facing competition from foreign organisations in their domestic markets. The adverse effects of this competition stem, in part, from the low levels of productivity which characterise South African industry and which is well documented by the National Productivity Institute of South Africa. The concept of continuous improvement offers a proven methodology for increasing the effectiveness and efficiency of production processes. Given the situation that faces South African producers, it would seem appropriate to investigate how the concept of continuous improvement can be applied to a specific South African manufacturing organisation, like the Aspen Pharmacare General Facility, in order to improve its effectiveness and efficiency.
- Full Text:
- Date Issued: 2006
- Authors: Jozaffe, Lyndon Brian
- Date: 2006
- Subjects: Production management , Industrial efficiency
- Language: English
- Type: Thesis , Masters , MBA
- Identifier: vital:8557 , http://hdl.handle.net/10948/529 , Production management , Industrial efficiency
- Description: South African producers are constantly facing competition from foreign organisations in their domestic markets. The adverse effects of this competition stem, in part, from the low levels of productivity which characterise South African industry and which is well documented by the National Productivity Institute of South Africa. The concept of continuous improvement offers a proven methodology for increasing the effectiveness and efficiency of production processes. Given the situation that faces South African producers, it would seem appropriate to investigate how the concept of continuous improvement can be applied to a specific South African manufacturing organisation, like the Aspen Pharmacare General Facility, in order to improve its effectiveness and efficiency.
- Full Text:
- Date Issued: 2006
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