Analysis of performance management system at a local manufacturing company
- Authors: Muyengwa, Goodwell
- Date: 2014
- Subjects: Performance management , Manufacturing
- Type: Article
- Identifier: uj:4756 , http://hdl.handle.net/10210/11742
- Description: Effective use of performance management (measurement) system enables companies to improve on their competitiveness in the marketplace. Through a case study research, the paper reviews the performance management system of a local manufacturing company. Most researchers have focussed on wide range of performance management surveys and few paid attention to individual companies, which is the focus of this paper. The balanced score card framework was used to evaluate both internal business processes and external outcomes. Four perspectives of the scorecard; financial, customer, process and learning were looked into. The paper established that top management is clear and committed to the company’s strategy and goals. The company is struggling to increase its market share due to lower levels of productivity. High levels of rework were noticed on the shop-floor and are impacting negatively on their cash-flow. These problems have led to poor customer retention due to unmet delivery dates. The paper proposes that the company must initiate staff development programmes to enable a culture of continuous improvement.
- Full Text: false
- Authors: Muyengwa, Goodwell
- Date: 2014
- Subjects: Performance management , Manufacturing
- Type: Article
- Identifier: uj:4756 , http://hdl.handle.net/10210/11742
- Description: Effective use of performance management (measurement) system enables companies to improve on their competitiveness in the marketplace. Through a case study research, the paper reviews the performance management system of a local manufacturing company. Most researchers have focussed on wide range of performance management surveys and few paid attention to individual companies, which is the focus of this paper. The balanced score card framework was used to evaluate both internal business processes and external outcomes. Four perspectives of the scorecard; financial, customer, process and learning were looked into. The paper established that top management is clear and committed to the company’s strategy and goals. The company is struggling to increase its market share due to lower levels of productivity. High levels of rework were noticed on the shop-floor and are impacting negatively on their cash-flow. These problems have led to poor customer retention due to unmet delivery dates. The paper proposes that the company must initiate staff development programmes to enable a culture of continuous improvement.
- Full Text: false
Challenges and opportunities in implementing engineering systems thinking in design, manufacturing and process industries in Zimbabwe
- Nyemba, Wilson R., Mbohwa, Charles
- Authors: Nyemba, Wilson R. , Mbohwa, Charles
- Date: 2017
- Subjects: Engineering , Manufacturing , Systems thinking
- Language: English
- Type: Conference proceedings
- Identifier: http://hdl.handle.net/10210/258916 , uj:27231 , Citation: Nyemba, W.R. & Mbohwa, C. 2017. Challenges and opportunities in implementing engineering systems thinking in design, manufacturing and process industries in Zimbabwe.
- Description: Abstract: Engineering and manufacturing companies in industrializing countries such as Zimbabwe, largely employ traditional methods as well as conventional machine tools. Research carried out at five companies in Zimbabwe specializing in different business operations, similarly revealed that although such methods and tools are still applicable and productive, the processes are time consuming and the conventional machines often break down thereby delaying production. However, the research, which was conducted through interviews, direct observations as well as surveys, also revealed disconnections in 3 aspects of company policies, techniques employed and continuous professional development training. The research focused on establishing the challenges faced by the companies in implementing holistic approaches encompassing and integrating these 3 aspects. Recommendations were made for turning the various challenges into opportunities through adopting engineering systems thinking for integrating these aspects in order to improve capacity utilization, productivity and efficiency in the various companies.
- Full Text:
- Authors: Nyemba, Wilson R. , Mbohwa, Charles
- Date: 2017
- Subjects: Engineering , Manufacturing , Systems thinking
- Language: English
- Type: Conference proceedings
- Identifier: http://hdl.handle.net/10210/258916 , uj:27231 , Citation: Nyemba, W.R. & Mbohwa, C. 2017. Challenges and opportunities in implementing engineering systems thinking in design, manufacturing and process industries in Zimbabwe.
- Description: Abstract: Engineering and manufacturing companies in industrializing countries such as Zimbabwe, largely employ traditional methods as well as conventional machine tools. Research carried out at five companies in Zimbabwe specializing in different business operations, similarly revealed that although such methods and tools are still applicable and productive, the processes are time consuming and the conventional machines often break down thereby delaying production. However, the research, which was conducted through interviews, direct observations as well as surveys, also revealed disconnections in 3 aspects of company policies, techniques employed and continuous professional development training. The research focused on establishing the challenges faced by the companies in implementing holistic approaches encompassing and integrating these 3 aspects. Recommendations were made for turning the various challenges into opportunities through adopting engineering systems thinking for integrating these aspects in order to improve capacity utilization, productivity and efficiency in the various companies.
- Full Text:
Data collection and statistical data analysis in preparation for simulation of a furniture manufacturing company
- Nyemba, Wilson R., Mbohwa, Charles
- Authors: Nyemba, Wilson R. , Mbohwa, Charles
- Date: 2016
- Subjects: Data collection , Manufacturing , Statistical analysis
- Language: English
- Type: Conference proceedings
- Identifier: http://hdl.handle.net/10210/91956 , uj:20166 , Citation: Nyemba, W.R. & Mbohwa, C. 2016. Data collection and statistical data analysis in preparation for simulation of a furniture manufacturing company
- Description: Abstract: Systems that are simulated are generally made up of one or more elements that have some uncertainty associated with them. These systems may eventually evolve in a manner that is not completely predictable and thus become stochastic in nature. Simulation of stochastic systems requires that the variability of the elements in the system be characterized by probability distributions or concepts. An 'As- Is-Analysis' of the plant layout and product process flows was carried out at a furniture manufacturing company. Process data for four of their main products namely, pallets, baby tenders bunk beds and standard coffins was collected using a specially designed data sheet. An analysis of the product flow times was carried out by grouping the data into four time variables namely, material movement, processing and waiting (idle) times before and after processing at the active workstation. The distributions of these variables were obtained using graphical methods in which smooth distribution curves were generated. The gamma distribution with shape parameters of α= 3 and α=2 characterized the baby tenders while the product flow times for pallets were characterized by both the gamma distribution, α=3 and the exponential distribution with the mean varying between 14.95 and 271.78 seconds. All the data and analysis carried out produced useful information for input to the design of experiments for simulation.
- Full Text:
- Authors: Nyemba, Wilson R. , Mbohwa, Charles
- Date: 2016
- Subjects: Data collection , Manufacturing , Statistical analysis
- Language: English
- Type: Conference proceedings
- Identifier: http://hdl.handle.net/10210/91956 , uj:20166 , Citation: Nyemba, W.R. & Mbohwa, C. 2016. Data collection and statistical data analysis in preparation for simulation of a furniture manufacturing company
- Description: Abstract: Systems that are simulated are generally made up of one or more elements that have some uncertainty associated with them. These systems may eventually evolve in a manner that is not completely predictable and thus become stochastic in nature. Simulation of stochastic systems requires that the variability of the elements in the system be characterized by probability distributions or concepts. An 'As- Is-Analysis' of the plant layout and product process flows was carried out at a furniture manufacturing company. Process data for four of their main products namely, pallets, baby tenders bunk beds and standard coffins was collected using a specially designed data sheet. An analysis of the product flow times was carried out by grouping the data into four time variables namely, material movement, processing and waiting (idle) times before and after processing at the active workstation. The distributions of these variables were obtained using graphical methods in which smooth distribution curves were generated. The gamma distribution with shape parameters of α= 3 and α=2 characterized the baby tenders while the product flow times for pallets were characterized by both the gamma distribution, α=3 and the exponential distribution with the mean varying between 14.95 and 271.78 seconds. All the data and analysis carried out produced useful information for input to the design of experiments for simulation.
- Full Text:
Design of a 10-digit inventory codification system for a tube and pipe manufacturing company in Zimbabwe
- Nyemba, Wilson R., Mbohwa, Charles
- Authors: Nyemba, Wilson R. , Mbohwa, Charles
- Date: 2017
- Subjects: Inventory control , Manufacturing , Maintenance
- Language: English
- Type: Conference proceedings
- Identifier: http://hdl.handle.net/10210/224997 , uj:22714 , Citation: Nyemba, W.R. & Mbohwa, C. 2017. Design of a 10-digit inventory codification system for a tube and pipe manufacturing company in Zimbabwe. 14th Global Conference on Sustainable Manufacturing, GCSM 3-5 October 2016, Stellenbosch, South Africa. DOI: 10.1016/j.promfg.2017.02.064. , ISSN: 2351-9789
- Description: Abstract: Lack of proper inventory control usually leads to high stock-outs resulting in ‘firefighting’. This paper looks at the engineering and technical services required to maintain smooth production with the aim of developing an inventory control system for the efficient utilization of resources. A work study was carried out at a tube and pipe manufacturing company in Zimbabwe followed by an analysis outlining the operations, limitations and process flows. An inventory audit provided some insights on the company’s inventory control status. A 10-digit inventory codification system was designed based on 7 rules for generic application and capability for ‘make or buy’ decisions on spare parts. A cost benefit analysis revealed that although the project would initially be costly, a reduction in inventory can be realized through removal of slow moving and obsolete stock, realizing some annual savings in the long run, coupled with an improvement in record keeping and accountability.Lack of proper inventory control usually leads to high stock-outs resulting in ‘firefighting’. This paper looks at the engineering and technical services required to maintain smooth production with the aim of developing an inventory control system for the efficient utilization of resources. A work study was carried out at a tube and pipe manufacturing company in Zimbabwe followed by an analysis outlining the operations, limitations and process flows. An inventory audit provided some insights on the company’s inventory control status. A 10-digit inventory codification system was designed based on 7 rules for generic application and capability for ‘make or buy’ decisions on spare parts. A cost benefit analysis revealed that although the project would initially be costly, a reduction in inventory can be realized through removal of slow moving and obsolete stock, realizing some annual savings in the long run, coupled with an improvement in record keeping and accountability.
- Full Text:
- Authors: Nyemba, Wilson R. , Mbohwa, Charles
- Date: 2017
- Subjects: Inventory control , Manufacturing , Maintenance
- Language: English
- Type: Conference proceedings
- Identifier: http://hdl.handle.net/10210/224997 , uj:22714 , Citation: Nyemba, W.R. & Mbohwa, C. 2017. Design of a 10-digit inventory codification system for a tube and pipe manufacturing company in Zimbabwe. 14th Global Conference on Sustainable Manufacturing, GCSM 3-5 October 2016, Stellenbosch, South Africa. DOI: 10.1016/j.promfg.2017.02.064. , ISSN: 2351-9789
- Description: Abstract: Lack of proper inventory control usually leads to high stock-outs resulting in ‘firefighting’. This paper looks at the engineering and technical services required to maintain smooth production with the aim of developing an inventory control system for the efficient utilization of resources. A work study was carried out at a tube and pipe manufacturing company in Zimbabwe followed by an analysis outlining the operations, limitations and process flows. An inventory audit provided some insights on the company’s inventory control status. A 10-digit inventory codification system was designed based on 7 rules for generic application and capability for ‘make or buy’ decisions on spare parts. A cost benefit analysis revealed that although the project would initially be costly, a reduction in inventory can be realized through removal of slow moving and obsolete stock, realizing some annual savings in the long run, coupled with an improvement in record keeping and accountability.Lack of proper inventory control usually leads to high stock-outs resulting in ‘firefighting’. This paper looks at the engineering and technical services required to maintain smooth production with the aim of developing an inventory control system for the efficient utilization of resources. A work study was carried out at a tube and pipe manufacturing company in Zimbabwe followed by an analysis outlining the operations, limitations and process flows. An inventory audit provided some insights on the company’s inventory control status. A 10-digit inventory codification system was designed based on 7 rules for generic application and capability for ‘make or buy’ decisions on spare parts. A cost benefit analysis revealed that although the project would initially be costly, a reduction in inventory can be realized through removal of slow moving and obsolete stock, realizing some annual savings in the long run, coupled with an improvement in record keeping and accountability.
- Full Text:
Essays on industrialisation and deindustrialisation
- Callaghan, Christian William
- Authors: Callaghan, Christian William
- Date: 2020
- Subjects: Industrialization , Deindustrialization , Globalization , Manufacturing
- Language: English
- Type: Doctoral (Thesis)
- Identifier: http://hdl.handle.net/10210/448607 , uj:39365
- Description: Abstract: The primary objective of this thesis is to test what determines industrial development and the extent to which industrialisation drives important country-level economic outcomes such as growth, globalisation, and poverty reduction. Global evidence indicates an inverted-U shaped relationship between countries’ level of income per capita and the share of manufacturing in GDP. There is, however, substantial heterogeneity associated with individual country experiences. Given this heterogeneity, it is unclear as to how the determinants of manufacturing’s share of gross domestic product differ across country groups at different levels of development, and if there are regional differences in these determinants. To test these relationships, Chapter 2 investigates differences in determinants of manufacturing for a world sample of 100 countries for the period 1970-2014. The study applies country fixed effects panel regression analysis to sixteen sub-groups of countries differentiated by stage of development, regions and endowments. The results reveal important differences in the determinants of manufacturing’s share, particularly for countries at different stages of development. Findings also contest the assumption that a common path of manufacturing-led development might be available to countries at all levels of development... , D.Phil. (Economics)
- Full Text:
- Authors: Callaghan, Christian William
- Date: 2020
- Subjects: Industrialization , Deindustrialization , Globalization , Manufacturing
- Language: English
- Type: Doctoral (Thesis)
- Identifier: http://hdl.handle.net/10210/448607 , uj:39365
- Description: Abstract: The primary objective of this thesis is to test what determines industrial development and the extent to which industrialisation drives important country-level economic outcomes such as growth, globalisation, and poverty reduction. Global evidence indicates an inverted-U shaped relationship between countries’ level of income per capita and the share of manufacturing in GDP. There is, however, substantial heterogeneity associated with individual country experiences. Given this heterogeneity, it is unclear as to how the determinants of manufacturing’s share of gross domestic product differ across country groups at different levels of development, and if there are regional differences in these determinants. To test these relationships, Chapter 2 investigates differences in determinants of manufacturing for a world sample of 100 countries for the period 1970-2014. The study applies country fixed effects panel regression analysis to sixteen sub-groups of countries differentiated by stage of development, regions and endowments. The results reveal important differences in the determinants of manufacturing’s share, particularly for countries at different stages of development. Findings also contest the assumption that a common path of manufacturing-led development might be available to countries at all levels of development... , D.Phil. (Economics)
- Full Text:
Evaluating the impact of TPM in a railway and mining component manufacturing company
- Mawane, Yvonie N., Muyengwa, Goodwell
- Authors: Mawane, Yvonie N. , Muyengwa, Goodwell
- Date: 2018
- Subjects: TPM , Equipment reliability , Manufacturing
- Language: English
- Type: Conference proceeding
- Identifier: http://hdl.handle.net/10210/290800 , uj:31575 , Citation: Mawane, Y.N. & Muyengwa, G. 2018. Evaluating the impact of TPM in a railway and mining component manufacturing company.
- Description: Abstract: This paper evaluates the impact of Total Productive Maintenance (TPM) in a railway and mining component manufacturing company. Literature suggest that TPM is an approach innovative to maintenance and its major goals are no defects, no accidents and no breakdowns. Many authors have argued that TPM improves quality, equipment productivity, prevents unexpected breakdowns and reduces defects. Reliable manufacturing equipment is considered as a major contributor to the profitability and performance of manufacturing systems in today’s extremely evolving environment. Most organizations function effectively today because the equipment is reliable and available thereby maximising production throughput and profit. A case study was conducted and it involved a mixed method approach where both quantitative and qualitative data was gathered and analysed. The company implemented TPM through the following initiatives; autonomous maintenance, employee improvement, planned maintenance, quality maintenance, education and training and safety and health. TPM was implemented for eighteen months. This study made use of the following maintenance improvement tools, TPM, Failure Mode Effects and Critically Analysis (FMECA) and cause and effect diagram. Maintenance performance factor such as Overall Equipment Effectiveness (OEE) was analysed before and after TPM implementation. The results of this study showed that TPM implementation contributes to equipment reliability. There was an improvement in overall organizational performance. Through FMECA, maintenance tasks were prioritized and risk priority numbers (RPN) were calculated for particular equipment. Key performance indicators such as productivity and OEE were on an upward trend while there was a reduction in defect rates. Communication among workers, workers and management, and among different departments was improved. Worker motivation was improved through autonomous maintenance. However maintenance performance in some departments was found to be too low due to unavailability of data and worker inconsistency. This paper contributes to the theory and practice of TPM implementation.
- Full Text:
- Authors: Mawane, Yvonie N. , Muyengwa, Goodwell
- Date: 2018
- Subjects: TPM , Equipment reliability , Manufacturing
- Language: English
- Type: Conference proceeding
- Identifier: http://hdl.handle.net/10210/290800 , uj:31575 , Citation: Mawane, Y.N. & Muyengwa, G. 2018. Evaluating the impact of TPM in a railway and mining component manufacturing company.
- Description: Abstract: This paper evaluates the impact of Total Productive Maintenance (TPM) in a railway and mining component manufacturing company. Literature suggest that TPM is an approach innovative to maintenance and its major goals are no defects, no accidents and no breakdowns. Many authors have argued that TPM improves quality, equipment productivity, prevents unexpected breakdowns and reduces defects. Reliable manufacturing equipment is considered as a major contributor to the profitability and performance of manufacturing systems in today’s extremely evolving environment. Most organizations function effectively today because the equipment is reliable and available thereby maximising production throughput and profit. A case study was conducted and it involved a mixed method approach where both quantitative and qualitative data was gathered and analysed. The company implemented TPM through the following initiatives; autonomous maintenance, employee improvement, planned maintenance, quality maintenance, education and training and safety and health. TPM was implemented for eighteen months. This study made use of the following maintenance improvement tools, TPM, Failure Mode Effects and Critically Analysis (FMECA) and cause and effect diagram. Maintenance performance factor such as Overall Equipment Effectiveness (OEE) was analysed before and after TPM implementation. The results of this study showed that TPM implementation contributes to equipment reliability. There was an improvement in overall organizational performance. Through FMECA, maintenance tasks were prioritized and risk priority numbers (RPN) were calculated for particular equipment. Key performance indicators such as productivity and OEE were on an upward trend while there was a reduction in defect rates. Communication among workers, workers and management, and among different departments was improved. Worker motivation was improved through autonomous maintenance. However maintenance performance in some departments was found to be too low due to unavailability of data and worker inconsistency. This paper contributes to the theory and practice of TPM implementation.
- Full Text:
Impact of total productive maintenance (TPM) practices on manufacturing performance : a case study of manufacturing company
- Mwanza, Bupe G., Chanda, Hillary
- Authors: Mwanza, Bupe G. , Chanda, Hillary
- Date: 2015
- Subjects: Total productive management , Manufacturing , Total productive maintenance
- Language: English
- Type: Conference proceedings
- Identifier: http://hdl.handle.net/10210/55457 , uj:16293 , Citation: Mwanza, B.G. & Chanda, H. 2015. Impact of total productive maintenance (TPM) practices on manufacturing performance : a case study of manufacturing company. 1st National Conference on ISO and TQM, 7-9 Oct 2015 at the Zambezi Sun Hotel, Livingstone, hosted by The Copperbelt University (CBU), Zambia. , ISBN:962-86107-9-1-19
- Description: Abstract: Aim: Total Productive Management (TPM) is a strategic change management approach that has considerable impact on the internal efficiency of manufacturing organization, both in the developed countries and developing countries. It is an innovative maintenance program with a concept for maintaining plant and equipment by the involvement of all personnel based in an organization for continuous improvement of performance. The purpose of the research was to evaluate the impact TPM pillars have on equipment availability focusing on the planned maintenance pillar. The research objectives were to; determine how the planned maintenance pillar was used at the company under study and the extent to which it was applied; to determine the impact that TPM had on the company’s performance and finally to determine if the TPM pillars had helped in obtaining the overall expected results that rise from an effectively implemented TPM. Methodology: A literature survey was undertaken into the elements and benefits of TPM, the pillars of TPM and finally the importance of equipment availability and overall equipment effectiveness (OEE). A quantitative and qualitative research approach was used in conducting the research. Structured interviews, questionnaires and company records were used in collecting data for the research. A total of 40 questionnaires were administered; 10 to the maintenance personnel and 30 to respondents from other departments of the company. Research data was analyzed using statistical package for social sciences (SPSS) and Microsoft excel. Findings: The results from the research revealed the following, 42% of the respondents agreed a maintenance plan is prepared before any maintenance activity is carried out, 29% indicated a maintenance plan was not prepared before maintenance activities is carried out and the 29% indicated it was not prepared all the time. To determine whether planned maintenance was carried out according to schedule, 43% of the respondents indicated it was carried out according to schedule while 43% indicated planned maintenance are only carried out only when there is an equipment malfunction and 14% indicated planned maintenance actions are only carried out when need to perform maintenance arises. The researchers also the assessed how TPM had impacted on the company performance; 50% of the respondents believed TPM reduced equipment losses while 71% believed the system reduced equipment failures, 67% believed it improved productivity and 50% believed it reduced breakdown costs. As a result of implementing TPM strategy the company’s overall equipment effectiveness ranges from 51% to 55%. Originality: The originality of the research steams from the fact that, the research has never been conducted before at the company under study and also the reeacrh focuses on the relevance of the TPM planned maintenace pillar on the company manufacturing performance. Value: Firstly the value of this research was to inform management on the need to employ each TPM pillar with a degree of equal importance as the entire pillars play role in enabling a company achieve world class standards in terms of manufacturing performance and overall equipment effectiveness. Secondly it points out that practicing TPM strategies is one of the best practices to achieve world class manufacturing standards.
- Full Text:
- Authors: Mwanza, Bupe G. , Chanda, Hillary
- Date: 2015
- Subjects: Total productive management , Manufacturing , Total productive maintenance
- Language: English
- Type: Conference proceedings
- Identifier: http://hdl.handle.net/10210/55457 , uj:16293 , Citation: Mwanza, B.G. & Chanda, H. 2015. Impact of total productive maintenance (TPM) practices on manufacturing performance : a case study of manufacturing company. 1st National Conference on ISO and TQM, 7-9 Oct 2015 at the Zambezi Sun Hotel, Livingstone, hosted by The Copperbelt University (CBU), Zambia. , ISBN:962-86107-9-1-19
- Description: Abstract: Aim: Total Productive Management (TPM) is a strategic change management approach that has considerable impact on the internal efficiency of manufacturing organization, both in the developed countries and developing countries. It is an innovative maintenance program with a concept for maintaining plant and equipment by the involvement of all personnel based in an organization for continuous improvement of performance. The purpose of the research was to evaluate the impact TPM pillars have on equipment availability focusing on the planned maintenance pillar. The research objectives were to; determine how the planned maintenance pillar was used at the company under study and the extent to which it was applied; to determine the impact that TPM had on the company’s performance and finally to determine if the TPM pillars had helped in obtaining the overall expected results that rise from an effectively implemented TPM. Methodology: A literature survey was undertaken into the elements and benefits of TPM, the pillars of TPM and finally the importance of equipment availability and overall equipment effectiveness (OEE). A quantitative and qualitative research approach was used in conducting the research. Structured interviews, questionnaires and company records were used in collecting data for the research. A total of 40 questionnaires were administered; 10 to the maintenance personnel and 30 to respondents from other departments of the company. Research data was analyzed using statistical package for social sciences (SPSS) and Microsoft excel. Findings: The results from the research revealed the following, 42% of the respondents agreed a maintenance plan is prepared before any maintenance activity is carried out, 29% indicated a maintenance plan was not prepared before maintenance activities is carried out and the 29% indicated it was not prepared all the time. To determine whether planned maintenance was carried out according to schedule, 43% of the respondents indicated it was carried out according to schedule while 43% indicated planned maintenance are only carried out only when there is an equipment malfunction and 14% indicated planned maintenance actions are only carried out when need to perform maintenance arises. The researchers also the assessed how TPM had impacted on the company performance; 50% of the respondents believed TPM reduced equipment losses while 71% believed the system reduced equipment failures, 67% believed it improved productivity and 50% believed it reduced breakdown costs. As a result of implementing TPM strategy the company’s overall equipment effectiveness ranges from 51% to 55%. Originality: The originality of the research steams from the fact that, the research has never been conducted before at the company under study and also the reeacrh focuses on the relevance of the TPM planned maintenace pillar on the company manufacturing performance. Value: Firstly the value of this research was to inform management on the need to employ each TPM pillar with a degree of equal importance as the entire pillars play role in enabling a company achieve world class standards in terms of manufacturing performance and overall equipment effectiveness. Secondly it points out that practicing TPM strategies is one of the best practices to achieve world class manufacturing standards.
- Full Text:
Process mapping, modelling and optimization of plant layouts and materials handling in manufacturing
- Nyemba, Wilson R., Mbohwa, Charles, Nyemba, L. E. N.
- Authors: Nyemba, Wilson R. , Mbohwa, Charles , Nyemba, L. E. N.
- Date: 2018
- Subjects: Manufacturing , Materials handling , Modelling
- Language: English
- Type: Book chapter
- Identifier: http://hdl.handle.net/10210/270495 , uj:28752 , Citation: Nyemba, W.R., Mbohwa, C. & Nyemba, L.E.N. 2018. Process mapping, modelling and optimization of plant layouts and materials handling in manufacturing. In Book: Transactions on Engineering Sciences.
- Description: Abstract: Documenting process flows in a manufacturing environment provides a guide to understanding how processes are interconnected and how materials are handled, thus forming the basis for modelling and optimization in order to simplify the otherwise complex systems particularly in multi-product manufacturing. Research was carried out at a furniture manufacturing company specializing in the production of a wide range of furniture from hardwood. Owing to the multiplicity of processes and the movement of materials in manufacturing environments, the factors affecting such setups increasingly become complex, equally requiring complex techniques to analyze and optimize them. A work study carried out at the company established inherent problems that affected production and were used as the basis for modelling and optimizing the processes, focusing on grouping of workstations depending on functions, predicting performance using simulation and machine distance matrices for a reorganized plant layout. Results obtained after modelling and optimizing the plant layout were useful for production planning and control as well as enhancing the company’s productivity and efficiency.
- Full Text:
Process mapping, modelling and optimization of plant layouts and materials handling in manufacturing
- Authors: Nyemba, Wilson R. , Mbohwa, Charles , Nyemba, L. E. N.
- Date: 2018
- Subjects: Manufacturing , Materials handling , Modelling
- Language: English
- Type: Book chapter
- Identifier: http://hdl.handle.net/10210/270495 , uj:28752 , Citation: Nyemba, W.R., Mbohwa, C. & Nyemba, L.E.N. 2018. Process mapping, modelling and optimization of plant layouts and materials handling in manufacturing. In Book: Transactions on Engineering Sciences.
- Description: Abstract: Documenting process flows in a manufacturing environment provides a guide to understanding how processes are interconnected and how materials are handled, thus forming the basis for modelling and optimization in order to simplify the otherwise complex systems particularly in multi-product manufacturing. Research was carried out at a furniture manufacturing company specializing in the production of a wide range of furniture from hardwood. Owing to the multiplicity of processes and the movement of materials in manufacturing environments, the factors affecting such setups increasingly become complex, equally requiring complex techniques to analyze and optimize them. A work study carried out at the company established inherent problems that affected production and were used as the basis for modelling and optimizing the processes, focusing on grouping of workstations depending on functions, predicting performance using simulation and machine distance matrices for a reorganized plant layout. Results obtained after modelling and optimizing the plant layout were useful for production planning and control as well as enhancing the company’s productivity and efficiency.
- Full Text:
Production facility location strategies for small and medium sized sewing cooperatives to enhance operational performance
- Mkwanazi, Michael Sizwe, Mbohwa, Charles
- Authors: Mkwanazi, Michael Sizwe , Mbohwa, Charles
- Date: 2017
- Subjects: Cooperatives , Facilities , Manufacturing
- Language: English
- Type: Conference proceedings
- Identifier: http://hdl.handle.net/10210/232982 , uj:23776 , Citation: Mkwanazi, M.S. & Mbohwa, C. 2017. Production facility location strategies for small and medium sized sewing cooperatives to enhance operational performance.
- Description: Abstract: Small manufacturing cooperatives tend to encounter challenges when making production facility location decisions. The consideration of facility location factors when making location decisions is a challenge for smaller enterprises, their decision are based on the availability of funding and infrastructure. In this project, a total census 83 funded sewing cooperatives participated. The majority of these cooperatives perceived themselves as successful because they were still in operation and receiving contracts from time to time. Incubators and facilitysharing, are strategies suggested for new sewing cooperatives, to avoid the mistakes associated with home-based business operations. Operations and green practices in sewing cooperatives would make a substantial contribution to the creation of knowledge about sewing and clothing cooperatives, given the interest of South African government to revitalize manufacturing and that of the United Nations of creating an inclusive economy through cooperatives.
- Full Text:
- Authors: Mkwanazi, Michael Sizwe , Mbohwa, Charles
- Date: 2017
- Subjects: Cooperatives , Facilities , Manufacturing
- Language: English
- Type: Conference proceedings
- Identifier: http://hdl.handle.net/10210/232982 , uj:23776 , Citation: Mkwanazi, M.S. & Mbohwa, C. 2017. Production facility location strategies for small and medium sized sewing cooperatives to enhance operational performance.
- Description: Abstract: Small manufacturing cooperatives tend to encounter challenges when making production facility location decisions. The consideration of facility location factors when making location decisions is a challenge for smaller enterprises, their decision are based on the availability of funding and infrastructure. In this project, a total census 83 funded sewing cooperatives participated. The majority of these cooperatives perceived themselves as successful because they were still in operation and receiving contracts from time to time. Incubators and facilitysharing, are strategies suggested for new sewing cooperatives, to avoid the mistakes associated with home-based business operations. Operations and green practices in sewing cooperatives would make a substantial contribution to the creation of knowledge about sewing and clothing cooperatives, given the interest of South African government to revitalize manufacturing and that of the United Nations of creating an inclusive economy through cooperatives.
- Full Text:
Redesign and control of backtracking of process paths in manufacturing plant layouts for productivity and sustainability
- Nyemba, Wilson R., Maswera, M., Mbohwa, Charles
- Authors: Nyemba, Wilson R. , Maswera, M. , Mbohwa, Charles
- Date: 2017
- Subjects: Manufacturing , Process flow , Layout
- Language: English
- Type: Conference proceedings
- Identifier: http://hdl.handle.net/10210/258930 , uj:27233 , Citation: Nyemba, W.R., Maswera, M. & Mbohwa, C. 2017. Redesign and control of backtracking of process paths in manufacturing plant layouts for productivity and sustainability.
- Description: Abstract: The layout of workstations, sequence and flow of parts in a manufacturing environment have significant bearings on productivity and efficiency of manufacturing companies. Research carried out at a furniture manufacturing company in Zimbabwe revealed that parts and sub-assemblies in the plant traversed long distances during processing, exhibiting crisscrossing and backtracking of process flows. Coupled with the other challenges such as failure to provide timely product deliveries to meet customer demands, the research focused on redesigning the layout of workstations using simulation and group technology for prediction of performance, identification of bottlenecks and efficient utilization of space and resources. This was aimed at controlling the backtracking of process paths by reducing travel distances and lead times. The reorganized plant achieved an average 26.5% reduction in manufacturing lead times and 48% reduction in travel distances, which translated to improvements in productivity for the sustainable and competitive manufacture of furniture for the domestic and commercial market.
- Full Text:
- Authors: Nyemba, Wilson R. , Maswera, M. , Mbohwa, Charles
- Date: 2017
- Subjects: Manufacturing , Process flow , Layout
- Language: English
- Type: Conference proceedings
- Identifier: http://hdl.handle.net/10210/258930 , uj:27233 , Citation: Nyemba, W.R., Maswera, M. & Mbohwa, C. 2017. Redesign and control of backtracking of process paths in manufacturing plant layouts for productivity and sustainability.
- Description: Abstract: The layout of workstations, sequence and flow of parts in a manufacturing environment have significant bearings on productivity and efficiency of manufacturing companies. Research carried out at a furniture manufacturing company in Zimbabwe revealed that parts and sub-assemblies in the plant traversed long distances during processing, exhibiting crisscrossing and backtracking of process flows. Coupled with the other challenges such as failure to provide timely product deliveries to meet customer demands, the research focused on redesigning the layout of workstations using simulation and group technology for prediction of performance, identification of bottlenecks and efficient utilization of space and resources. This was aimed at controlling the backtracking of process paths by reducing travel distances and lead times. The reorganized plant achieved an average 26.5% reduction in manufacturing lead times and 48% reduction in travel distances, which translated to improvements in productivity for the sustainable and competitive manufacture of furniture for the domestic and commercial market.
- Full Text:
Technological changes and manufacturing unions in South Africa : failure to formulate a robust response
- Authors: Hlatshwayo, Mondli
- Date: 2017
- Subjects: Manufacturing , Unions , Technology
- Language: English
- Type: Article
- Identifier: http://hdl.handle.net/10210/263326 , uj:27836 , Citation: Hlatshwayo, M. 2017. Technological changes and manufacturing unions in South Africa: failure to formulate a robust response. Global Labour Journal, 8(2):100-119.
- Description: Abstract: Technological innovation has had far-reaching implications for labour and for the world of work generally. It has led to job losses, the creation of new jobs, the loss of some skilled positions and the creation of new ones, and an increase in the quality of products like steel. Literature that addresses union responses to technological innovation in production has tended to classify them as either reactive or proactive, with reactive responses predominating. This article examines how South African trade unions in the steel, automotive and chemical industries have responded to technological changes. Based on interviews and documentary analysis, it argues that the unions have adopted a rearguard approach, responding to technological changes only after management has already implemented them. Unions have tended to prioritise “politics from above” and traditional union issues such as wage negotiations. In addition, the current division within unions has contributed to their inability to improve their servicing of members, let alone organise precarious workers and engage with issues of technological innovation.
- Full Text:
- Authors: Hlatshwayo, Mondli
- Date: 2017
- Subjects: Manufacturing , Unions , Technology
- Language: English
- Type: Article
- Identifier: http://hdl.handle.net/10210/263326 , uj:27836 , Citation: Hlatshwayo, M. 2017. Technological changes and manufacturing unions in South Africa: failure to formulate a robust response. Global Labour Journal, 8(2):100-119.
- Description: Abstract: Technological innovation has had far-reaching implications for labour and for the world of work generally. It has led to job losses, the creation of new jobs, the loss of some skilled positions and the creation of new ones, and an increase in the quality of products like steel. Literature that addresses union responses to technological innovation in production has tended to classify them as either reactive or proactive, with reactive responses predominating. This article examines how South African trade unions in the steel, automotive and chemical industries have responded to technological changes. Based on interviews and documentary analysis, it argues that the unions have adopted a rearguard approach, responding to technological changes only after management has already implemented them. Unions have tended to prioritise “politics from above” and traditional union issues such as wage negotiations. In addition, the current division within unions has contributed to their inability to improve their servicing of members, let alone organise precarious workers and engage with issues of technological innovation.
- Full Text:
The feasibility of adopting clothing mass customisation in South Africa
- Authors: Aoun, M. , Thomas, P.
- Date: 2019
- Subjects: Technology , Innovation , Manufacturing
- Language: English
- Type: Conference proceedings
- Identifier: http://hdl.handle.net/10210/404627 , uj:33940 , Citation: Aoun, M. & Thomas, P. 2019. The feasibility of adopting clothing mass customisation in South Africa.
- Description: Abstract: Mass Customisation (MC) is increasingly seen as a strategy to survive in the competitive clothing fashion markets. This importance to retail sales necessitates its consideration in the South African context. There is a paucity of literature on adopting MC so exploring the feasibility of MC for South African clothing manufacturers was a step in understanding what is required from manufacturers. Three corporate clothing manufacturers were selected for qualitative interviews to determine whether they currently exhibit identified competencies from literature considered essential to undertake MC. Two manufacturers exhibited key competencies of communication, human capital, flexibility and technology needed for MC success.
- Full Text:
- Authors: Aoun, M. , Thomas, P.
- Date: 2019
- Subjects: Technology , Innovation , Manufacturing
- Language: English
- Type: Conference proceedings
- Identifier: http://hdl.handle.net/10210/404627 , uj:33940 , Citation: Aoun, M. & Thomas, P. 2019. The feasibility of adopting clothing mass customisation in South Africa.
- Description: Abstract: Mass Customisation (MC) is increasingly seen as a strategy to survive in the competitive clothing fashion markets. This importance to retail sales necessitates its consideration in the South African context. There is a paucity of literature on adopting MC so exploring the feasibility of MC for South African clothing manufacturers was a step in understanding what is required from manufacturers. Three corporate clothing manufacturers were selected for qualitative interviews to determine whether they currently exhibit identified competencies from literature considered essential to undertake MC. Two manufacturers exhibited key competencies of communication, human capital, flexibility and technology needed for MC success.
- Full Text:
Use of six-sigma concept in discrete manufacturing industry
- Mbohwa, Charles, Madanhire, Ignatio
- Authors: Mbohwa, Charles , Madanhire, Ignatio
- Date: 2014
- Subjects: Manufacturing , Six Sigma methodology
- Type: Article
- Identifier: uj:5031 , http://hdl.handle.net/10210/13551
- Description: Efficiency in manufacturing is critical in raising the value of exports so as to gainfully trade on the regional and international markets. There seems to be increasing popularity of continuous improvement strategies availed to manufacturing entities, but this research study established that there has not been a similar popularity accorded to the Six Sigma methodology. Thus this work was conducted to investigate the applicability, effectiveness, usefulness, application and suitability of the Six Sigma methodology as a competitiveness option for discrete manufacturing entity. Development of Six-sigma center in the country with continuous improvement information would go a long way in benefiting the entire industry.
- Full Text:
- Authors: Mbohwa, Charles , Madanhire, Ignatio
- Date: 2014
- Subjects: Manufacturing , Six Sigma methodology
- Type: Article
- Identifier: uj:5031 , http://hdl.handle.net/10210/13551
- Description: Efficiency in manufacturing is critical in raising the value of exports so as to gainfully trade on the regional and international markets. There seems to be increasing popularity of continuous improvement strategies availed to manufacturing entities, but this research study established that there has not been a similar popularity accorded to the Six Sigma methodology. Thus this work was conducted to investigate the applicability, effectiveness, usefulness, application and suitability of the Six Sigma methodology as a competitiveness option for discrete manufacturing entity. Development of Six-sigma center in the country with continuous improvement information would go a long way in benefiting the entire industry.
- Full Text:
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