Abstract
The ability to successfully manage a production ramp-up has become very crucial in order for manufacturing companies to compete in today’s fast paced manufacturing industry. Competition among manufacturers has led to a decrease in the product life cycle, leading to a need for a shortened production ramp-up period [1]. When reviewing previous research, it has become evident that there is a huge gap regarding the knowledge and skills required in order to successfully manage a production ramp-up. As a result, most production ramp-ups end up being unsuccessful. When managing a production ramp-up, the aim is to meet the expected production ramp-up targets by facilitating decisions that would lead to the best possible management of cost, time and resourses. For this to be accomplished, there is a need for a production ramp-up management framework. In this research, the relative impact of six production ramp-up challenges were identified as well as the extent in which each of the six identified ramp-up management startegies can be used to address these challenges. The analytical hierarchy process (AHP) is used for ranking the ramp-up challenges based on time and cost impact during a production ramp-up, ramp-up management startegies were also ranked based on time saved, cost saved and ease of implementation. A online survey was used to collect responses from 19 participants, all the participants were individuals currently employed in the manufacturing industry. The final priority results for the impact of ramp-up challenges and ramp-up strategies were obtained and discussed. From the AHP analysis, it was found that the common ramp-up challenges faced by the participants are the lack of ramp-up experience and the complexity of the facility. It was also identified by the participants that the volume first strategy provides the most value during a production ramp-up, followed by the shutdown strategy. More literature was then reviewed in order to link the specific production ramp-up challenges to the relevant ramp-up management strategies. Results from the literature and the Analytical hierarchy process were used to develope a readiness framework for a production ramp-up. This framework will help manuafacturing companies to successfully plan and manage production ramp-ups.
M.Ing. (Engineering Management)