Increasing warehouse performance by effective order picking system : case study of South African steel manufacturing sector
- Authors: Magoro, Nakedi Macdonald
- Date: 2019
- Subjects: Warehouses - Management , Steel industry and trade - Management
- Language: English
- Type: Masters (Thesis)
- Identifier: http://hdl.handle.net/10210/430722 , uj:37136
- Description: Abstract: Warehouse plays one of the most vital part in any organization; it plays a fundamental role in facilitating global trade. A firm with a viable warehouse management system can easily meet customers demand. It also makes sure that the goods are readily available and delivered faster at a reasonable price to a network of global clients. However, if it is not properly structured and managed, it can cause a company not to be able to compete competitively globally. To this end, the overall aim of this study is to explore factors affecting warehouse performance to gain competitive market advantage. However, it was discovered that, warehouse management as a core enabler of manufacturing competitiveness continues to be under-appreciated by top management. To achieve the aforementioned goal, this study adopted a two-fold approach, firstly the study critically analysed a set of previous studies that were conducted on the warehouse management system within various business organisations. This helped in identifying gaps existing in the current literature. Secondly, the study used quantitative interviews with various experts from different manufacturing firms in order to address the identified flaws. The data collected from various consultations with industrial experts were analysed using deductive reasoning techniques. Manufacturing industry used a case study with three different firms located in South Africa, particularly in the province of Gauteng. The participants that took part in this study were chosen by means of convenience sampling approach. This method is preferred due to its ability to give the researcher an opportunity to select participants that were easily accessible. The initial findings of this study have revealed that the current warehouse management system put in place by most of the South African steel manufacturing firms is unintegrated and unautomated, and also formal picking systems is not in place, which in return hinders the industry from gaining global competitive market advantage. Additionally, the results demonstrated that there is a lack of zone pickings, which causes many movements and consequently damages the warehouse system. Furthermore, it was observed that most of staff working within the warehouse division are technology illiterate, which also create many delays. Despite, the fact that we live in a highly digitalized century, it is worrying to note that the appetite to adopt digital-based Warehouse Management System (WMS) is very low. It Is further recommended that Warehouse Management Systems (WMS) be introduced, it is a software-based application that is used to manage, control and manipulate warehouse processes, procedures in a way that deliver greater cost efficiencies to a manufacturing firm. .. , M.Tech. (Quality and Operations Management)
- Full Text:
- Authors: Magoro, Nakedi Macdonald
- Date: 2019
- Subjects: Warehouses - Management , Steel industry and trade - Management
- Language: English
- Type: Masters (Thesis)
- Identifier: http://hdl.handle.net/10210/430722 , uj:37136
- Description: Abstract: Warehouse plays one of the most vital part in any organization; it plays a fundamental role in facilitating global trade. A firm with a viable warehouse management system can easily meet customers demand. It also makes sure that the goods are readily available and delivered faster at a reasonable price to a network of global clients. However, if it is not properly structured and managed, it can cause a company not to be able to compete competitively globally. To this end, the overall aim of this study is to explore factors affecting warehouse performance to gain competitive market advantage. However, it was discovered that, warehouse management as a core enabler of manufacturing competitiveness continues to be under-appreciated by top management. To achieve the aforementioned goal, this study adopted a two-fold approach, firstly the study critically analysed a set of previous studies that were conducted on the warehouse management system within various business organisations. This helped in identifying gaps existing in the current literature. Secondly, the study used quantitative interviews with various experts from different manufacturing firms in order to address the identified flaws. The data collected from various consultations with industrial experts were analysed using deductive reasoning techniques. Manufacturing industry used a case study with three different firms located in South Africa, particularly in the province of Gauteng. The participants that took part in this study were chosen by means of convenience sampling approach. This method is preferred due to its ability to give the researcher an opportunity to select participants that were easily accessible. The initial findings of this study have revealed that the current warehouse management system put in place by most of the South African steel manufacturing firms is unintegrated and unautomated, and also formal picking systems is not in place, which in return hinders the industry from gaining global competitive market advantage. Additionally, the results demonstrated that there is a lack of zone pickings, which causes many movements and consequently damages the warehouse system. Furthermore, it was observed that most of staff working within the warehouse division are technology illiterate, which also create many delays. Despite, the fact that we live in a highly digitalized century, it is worrying to note that the appetite to adopt digital-based Warehouse Management System (WMS) is very low. It Is further recommended that Warehouse Management Systems (WMS) be introduced, it is a software-based application that is used to manage, control and manipulate warehouse processes, procedures in a way that deliver greater cost efficiencies to a manufacturing firm. .. , M.Tech. (Quality and Operations Management)
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Effect of TOC adoption in South Africa : a case study of Lonmin mine
- Authors: Ramasu, Tlotlo Keatlaretse
- Date: 2018
- Subjects: Theory of constraints (Management) , Platinum mines and mining - South Africa , Mine management - South Africa
- Language: English
- Type: Masters (Thesis)
- Identifier: http://ujcontent.uj.ac.za8080/10210/370367 , http://hdl.handle.net/10210/280277 , uj:30114
- Description: M.Tech. (Operations Management) , Abstract: South Africa currently has one of Africa’s largest economies. An enormous portion of this country’s economy is dependent on the natural land resources. Mining has and continues to be the pride of this nation setting them high up on the map and sustaining the economy, at some point controlling 37% of foreign investment. South Africa is one of the largest producers of platinum, gold, manganese, coal, zirconium, and a couple of other minerals. One of the world’s largest primary platinum producers is found in South Africa, named Lonmin. The dependence of the economy on minerals would put this organization together with others, under pressure to perform, and thus a great operations strategy is a good investment to this sector. In 2013, Lonmin introduced a new operation system called the Theory of Constraints (TOC). The purpose of this shift was to adopt a strategy that would optimize efficiency in this organization and TOC presented benefits that seemed to match the goals of this organization. TOC is a philosophy that is applied to debottleneck processes in order to ensure a more efficient flow, which aims to maximize the processing capacity. Lonmin’s 4B shaft and Saffy shaft were the two shafts used as a case study to determine if TOC is a practical strategy for optimization of organizational efficiency. SPC charts of the shafts were used to study the production trends over a period of 5 years. Questionnaires were used to study the consistency of TOC and the challenges that have hindered its maximum efficiency, employee reception, and the overall sustainability of this system based on the data previously collected from the SPC and questionnaires. Although factors such as attitude, training and understanding played a major role in the objectives of this study, this study was done with the primary purpose of determining whether or not TOC is an effective system in this organization. The results of the questionnaires were interpreted in frequency bar charts, custom tables, the independent t-test, reliability analysis and the exploratory factor analysis. The reliability analysis was used to validate the questions used to measure the attitude and perception of employees working in these shafts. The production outcome of these results were contradictory and thus the profitability of TOC is not conclusive. The production output on its own could not be considered since the trends..
- Full Text:
- Authors: Ramasu, Tlotlo Keatlaretse
- Date: 2018
- Subjects: Theory of constraints (Management) , Platinum mines and mining - South Africa , Mine management - South Africa
- Language: English
- Type: Masters (Thesis)
- Identifier: http://ujcontent.uj.ac.za8080/10210/370367 , http://hdl.handle.net/10210/280277 , uj:30114
- Description: M.Tech. (Operations Management) , Abstract: South Africa currently has one of Africa’s largest economies. An enormous portion of this country’s economy is dependent on the natural land resources. Mining has and continues to be the pride of this nation setting them high up on the map and sustaining the economy, at some point controlling 37% of foreign investment. South Africa is one of the largest producers of platinum, gold, manganese, coal, zirconium, and a couple of other minerals. One of the world’s largest primary platinum producers is found in South Africa, named Lonmin. The dependence of the economy on minerals would put this organization together with others, under pressure to perform, and thus a great operations strategy is a good investment to this sector. In 2013, Lonmin introduced a new operation system called the Theory of Constraints (TOC). The purpose of this shift was to adopt a strategy that would optimize efficiency in this organization and TOC presented benefits that seemed to match the goals of this organization. TOC is a philosophy that is applied to debottleneck processes in order to ensure a more efficient flow, which aims to maximize the processing capacity. Lonmin’s 4B shaft and Saffy shaft were the two shafts used as a case study to determine if TOC is a practical strategy for optimization of organizational efficiency. SPC charts of the shafts were used to study the production trends over a period of 5 years. Questionnaires were used to study the consistency of TOC and the challenges that have hindered its maximum efficiency, employee reception, and the overall sustainability of this system based on the data previously collected from the SPC and questionnaires. Although factors such as attitude, training and understanding played a major role in the objectives of this study, this study was done with the primary purpose of determining whether or not TOC is an effective system in this organization. The results of the questionnaires were interpreted in frequency bar charts, custom tables, the independent t-test, reliability analysis and the exploratory factor analysis. The reliability analysis was used to validate the questions used to measure the attitude and perception of employees working in these shafts. The production outcome of these results were contradictory and thus the profitability of TOC is not conclusive. The production output on its own could not be considered since the trends..
- Full Text:
Implementation of HACCP food safety system at Anheuser-Busch InBev Traditional African Beverages plants
- Authors: Radingoane, Leutle
- Date: 2018
- Language: English
- Type: Masters (Thesis)
- Identifier: http://hdl.handle.net/10210/296391 , uj:32291
- Description: Abstract: Food trading is one of the biggest emerging and congested businesses in both rural and urban areas of developed and developing nations worldwide and the opportunities for food businesses to be successful are greater than ever. Production of food is a complex process as it involves many different stages, such as receiving, handling and storage of unprocessed materials; the manufacturing process; packaging; storage; transportation; and the consumption of product, along with waste removal and disposal. This means that if the food safety control system of any company producing or handling food is weak or absent, food contaminations or hazards (such as biological, chemical and physical) are expected to happen at any stage of the process, and subsequently to result in unsafe food for consumption. Food safety is a confirmation that foodstuff cannot be detrimental to the end users if it is prepared, handled, served and consumed as per the instruction. However, a significant number of individuals worldwide still suffer from food-related illness owing to the availability of food safety hazards in the food network. In most parts of Africa, owing to high levels of unemployment and illiteracy, the majority of people have resorted to traditional and unsafe food and beer, which is produced and sold on the street. This has prompted AB-InBev Africa (formerly SABMiller) to produce and market traditional beer (Opaque), which is produced in a hygienic controlled environment as a way of migrating opaque beer drinkers from unsafe homemade beer to safe beer. However, the nature and viscosity of the opaque beer make the analytical and microbial capability to detect quality and food safety issues a challenge. A food safety system that is able to anticipate and manage the risks associated with food proactively and effectively needs to be installed in the processing plant. The whole intention of the study is to acquire a deep understanding into understanding of the process of implementation, quantify the challenges related to the implementation and subsequently tailor a model for the implementation of an HACCP food safety system at Traditional Africa Beer (TAB) and food manufacturing industries. A literature review employed to gain insights and understanding from the knowledge and findings emerging from previous research food safety and related studies. The literature review identified and defined the HACCP system as an effective and proactive plant- and process-based food safety programme for managing, analysing and eliminating food safety hazards before they enter products. The HACCP was found to be effective and efficient, if it gained the support of the top leadership of the organisation and was built on the solid foundation of effective prerequisite programmes (PRPs). Food safety systems that are based on HACCP principles are regarded as flexible and compatible with other international food safety standards such as International Organisation of standardisation (ISO) 22000 and 9000. Literature alerts us to the fact that the adoption and implementation of the food safety system is based on knowledge, expertise and understanding of the food manufacturing steps, current and probable food safety hazards and contaminants related to the production process, the HACCP principles and implementation steps, and installation of adequate PRPs. Prerequisites, which are based on the hygienic condition of the plant, play a critical role in reducing the number of hazards associated with the process and allow the HACCP to control critical control points (CCPs). The literature reviews also highlighted challenges and barriers to the HACCP food safety system implementation as results of poor seriousness by top management, lack of motivation by employees and insufficient and absence of resources, skills and training programmes, and no buy-in from employees. This study was guided by the theory of operation management, which addresses the planning, management and improvement of the manufacturing process to produce a safe food product. The literature was also used to explain the concepts of behavioural systems thinking and attribution theory as... , M.Tech.
- Full Text:
- Authors: Radingoane, Leutle
- Date: 2018
- Language: English
- Type: Masters (Thesis)
- Identifier: http://hdl.handle.net/10210/296391 , uj:32291
- Description: Abstract: Food trading is one of the biggest emerging and congested businesses in both rural and urban areas of developed and developing nations worldwide and the opportunities for food businesses to be successful are greater than ever. Production of food is a complex process as it involves many different stages, such as receiving, handling and storage of unprocessed materials; the manufacturing process; packaging; storage; transportation; and the consumption of product, along with waste removal and disposal. This means that if the food safety control system of any company producing or handling food is weak or absent, food contaminations or hazards (such as biological, chemical and physical) are expected to happen at any stage of the process, and subsequently to result in unsafe food for consumption. Food safety is a confirmation that foodstuff cannot be detrimental to the end users if it is prepared, handled, served and consumed as per the instruction. However, a significant number of individuals worldwide still suffer from food-related illness owing to the availability of food safety hazards in the food network. In most parts of Africa, owing to high levels of unemployment and illiteracy, the majority of people have resorted to traditional and unsafe food and beer, which is produced and sold on the street. This has prompted AB-InBev Africa (formerly SABMiller) to produce and market traditional beer (Opaque), which is produced in a hygienic controlled environment as a way of migrating opaque beer drinkers from unsafe homemade beer to safe beer. However, the nature and viscosity of the opaque beer make the analytical and microbial capability to detect quality and food safety issues a challenge. A food safety system that is able to anticipate and manage the risks associated with food proactively and effectively needs to be installed in the processing plant. The whole intention of the study is to acquire a deep understanding into understanding of the process of implementation, quantify the challenges related to the implementation and subsequently tailor a model for the implementation of an HACCP food safety system at Traditional Africa Beer (TAB) and food manufacturing industries. A literature review employed to gain insights and understanding from the knowledge and findings emerging from previous research food safety and related studies. The literature review identified and defined the HACCP system as an effective and proactive plant- and process-based food safety programme for managing, analysing and eliminating food safety hazards before they enter products. The HACCP was found to be effective and efficient, if it gained the support of the top leadership of the organisation and was built on the solid foundation of effective prerequisite programmes (PRPs). Food safety systems that are based on HACCP principles are regarded as flexible and compatible with other international food safety standards such as International Organisation of standardisation (ISO) 22000 and 9000. Literature alerts us to the fact that the adoption and implementation of the food safety system is based on knowledge, expertise and understanding of the food manufacturing steps, current and probable food safety hazards and contaminants related to the production process, the HACCP principles and implementation steps, and installation of adequate PRPs. Prerequisites, which are based on the hygienic condition of the plant, play a critical role in reducing the number of hazards associated with the process and allow the HACCP to control critical control points (CCPs). The literature reviews also highlighted challenges and barriers to the HACCP food safety system implementation as results of poor seriousness by top management, lack of motivation by employees and insufficient and absence of resources, skills and training programmes, and no buy-in from employees. This study was guided by the theory of operation management, which addresses the planning, management and improvement of the manufacturing process to produce a safe food product. The literature was also used to explain the concepts of behavioural systems thinking and attribution theory as... , M.Tech.
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Investigating the impact of environmental sustainability in South African chemical industry
- Authors: Chauke, Sindisiwe
- Date: 2018
- Subjects: Chemical industry - Environmental aspects - South Africa , Factory and trade waste - Environmental aspects - South Africa , Environmental sciences - South Africa , Chemical process control
- Language: English
- Type: Masters (Thesis)
- Identifier: http://hdl.handle.net/10210/280518 , uj:30144
- Description: Abstract: The study is based on the chemical companies in South Africa that have integrated the environmental sustainability principles into their business strategy. The aim of this study was to determine the effectiveness of environmental sustainability in South African chemical companies and investigate associated challenges and benefits in integrating environmental sustainability. Data were collected using questionnaire administered to 150 chemical companies’ representatives in four sub-sectors. The effectiveness of environmental sustainability in the chemical industry was measured using compliance to regulation, protection, protection of groundwater, effective hazardous waste management, improved health and safety of employees, availability of required resources, and full commitment of senior management. This study also investigated the impact that came with the implementation of environmental sustainability principles. The questionnaire was responded by 110 respondents out of which 98 were from Gauteng province. The main findings of the report were that the greatest challenges of integrating environmental sustainability principles in the chemical industry are lack of commitment from the senior management and resources of maintaining those principles. The study also found that benefits of integrating environmental sustainability principles are less legal issues, waste reduction, improved health and safety of employees, and competitive advantage. Lack of top management support was identified as the main barrier to effectively implementing and integrating environmental sustainability principles in chemical companies. The study found that the negative impact of integrating these... , M.Tech. (Operations Management)
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- Authors: Chauke, Sindisiwe
- Date: 2018
- Subjects: Chemical industry - Environmental aspects - South Africa , Factory and trade waste - Environmental aspects - South Africa , Environmental sciences - South Africa , Chemical process control
- Language: English
- Type: Masters (Thesis)
- Identifier: http://hdl.handle.net/10210/280518 , uj:30144
- Description: Abstract: The study is based on the chemical companies in South Africa that have integrated the environmental sustainability principles into their business strategy. The aim of this study was to determine the effectiveness of environmental sustainability in South African chemical companies and investigate associated challenges and benefits in integrating environmental sustainability. Data were collected using questionnaire administered to 150 chemical companies’ representatives in four sub-sectors. The effectiveness of environmental sustainability in the chemical industry was measured using compliance to regulation, protection, protection of groundwater, effective hazardous waste management, improved health and safety of employees, availability of required resources, and full commitment of senior management. This study also investigated the impact that came with the implementation of environmental sustainability principles. The questionnaire was responded by 110 respondents out of which 98 were from Gauteng province. The main findings of the report were that the greatest challenges of integrating environmental sustainability principles in the chemical industry are lack of commitment from the senior management and resources of maintaining those principles. The study also found that benefits of integrating environmental sustainability principles are less legal issues, waste reduction, improved health and safety of employees, and competitive advantage. Lack of top management support was identified as the main barrier to effectively implementing and integrating environmental sustainability principles in chemical companies. The study found that the negative impact of integrating these... , M.Tech. (Operations Management)
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